Inlays for security documents

ABSTRACT

Secure inlays for secure documents such as a passport comprising an inlay substrate may have laser ablated recesses within which a chip module is installed. Channels for an antenna wire may be formed in a surface of the substrate. Instead of using wire, the channels may be filled with a flowable, conductive material. Patches homogenous with the substrate layer may be used to protect and seal the chip and interconnection area. The inlay substrate may include two layers, and the antenna wire may be between the two layers. A moisture-curing polyurethane hot melt adhesive may be used to laminate a cover layer and the additional inlay substrate layers. The adhesive layer may include metal nanoscale powder and ink for electro-magnetic shielding. Additional security elements may include material that is optically changeable by an electro-magnetic field. Ferrite-containing layers may be incorporated in the inlay substrate.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a continuation of Ser. No. 12/545,825 filed Aug. 22, 2009, whichclaims priority from

-   -   61230,710 filed Aug. 2, 2009    -   61145,971 filed Jan. 21, 2009    -   61092,766 filed Aug. 29, 2008    -   61235,012 filed Aug. 19, 2009

TECHNICAL FIELD

The invention relates to “inlay substrates” used in the production of“inlays” for “security documents” such as electronic passports andelectronic identification cards.

BACKGROUND

A “security document” such as an electronic passport (ePassport) or anelectronic identification (eID) card may comprise an “inlay substrate”(or “inlay laminate”) which is typically a sheet (or layer) of materialsuch as Teslin™, with a Radio Frequency Identification (RFID) chipmodule and corresponding antenna mounted therein. An ePassport may havean additional “cover layer” (or “cover material”), such as PVC-coatedpaper, cloth or synthetic leather laminated (or joined) thereto. An eIDcard may have an additional upper “overlay layer” of anti-scratch,typically transparent material, with an adhesive backing laminatedthereto, and an additional “bottom layer”, which may have a magneticstripe.

In the main hereinafter, the inlay substrate (or inlay laminate) portionof security documents which are electronic passports (ePassport) arediscussed. The inlay substrate, with transponder module and antennaincorporated therein may be referred to as a “secure inlay”.

Examples of Some Secure Documents

An electronic passport cover (or “e-cover”) generally comprises a hingedcover comprising a front panel (or portion) and a back panel (orportion), and an insert of several pages disposed within the e-cover.The “passport card” is an alternative to an ordinary US passport cover.Both the passport cover and passport card include a vicinity-read radiofrequency identification (RFID) chip. The RFID chip in the passport card(eID card) is designed to be readable at a greater distance than that ofthe passport cover, and to prevent the RFID chip from being read whenthe passport card (eID card) is not being used, the passport card (eIDcard) typically comes with a sleeve designed to block the RFID chip frombeing read while the card is in the sleeve. See, for example, USPublished Application No. 2007/0205953, incorporated by referenceherein.

FIG. 1A shows an example of a security document which may an electronic“passport cover” (e-cover) comprising an inlay substrate (layer) and acover layer (cover material). An RFID chip module (not shown) andcorresponding antenna (not shown) may be mounted (disposed, embedded) inthe inlay substrate. An insert having several pages (not shown) forpresenting printed information and receiving visa (entry and exit)stamps may be mounted within the passport cover. Notice that thepassport cover, cover layer and inlay substrate may be folded, resultingin a front cover panel (portion) and a back cover panel (portion) of thepassport cover. The passport cover is shown partially open (partiallyclosed). In use, when being examined, scanned or stamped by a border(Vama, Duoanes) official, the passport cover may be fully open. When thepassport cover is closed, the cover layer is external to (surrounds) theinlay substrate. The passport cover, cover layer and inlay substrate arenot shown to scale.

FIG. 1B shows an example of a security document which may be anidentification (eID) card having an inlay substrate (layer), andadditional layers comprising a top overlay layer and a bottom layer. AnRFID chip module and corresponding antenna (not shown) may be mounted inthe inlay substrate (middle layer). The additional top and bottom layersmay be anti-scratch layers, and protect the inlay substrate in themiddle from top and bottom. The eID card, inlay substrate layer and topand bottom layers are not shown to scale.

Examples of Some RFID Chip Modules

In the main hereinafter, the discussion may focus on RFID chip moduleswhich are leadframe-type modules. However, some of the techniques forproducing security documents discussed herein may also be applicable toepoxy glass modules (chip on FR4, wire bonded, glob topped).

FIG. 1C shows an example of an RFID chip module which is a “leadframemodule” comprising:

-   -   a leadframe having a thickness of approximately 80 μm    -   an RFID chip disposed on and connected by wire bonds to the        leadframe, having a thickness of approximately 80 μm    -   a mold mass disposed over the chip and wire bonds, having a        thickness of approximately 240 μm    -   an antenna wire having end portions connected to “connection        areas” of the leadframe, typically on a side of the leadframe        opposite the RFID chip (as shown), but the end portions can also        be connected to connection areas on the same side of the lead        frame as the RFID chip.

The total thickness of the leadframe module may be 320 μm, such as foran inlay substrate having a thickness of approximately 356 μm.Generally, the chip module will be disposed in a recess in the inlaysubstrate so as to be concealed therein.

FIG. 1D shows an example of an RFID chip module which is an “epoxy glassmodule” comprising:

-   -   an interconnect substrate, such as FR4 (printed circuit board        substrate material), having a thickness of approximately 100 μm        (FR4 is 100 μm and the chip & glob top 160 μm=overall 260 μm)    -   an RFID chip, wire-bonded (alternatively flip-chip connected        with solder bumps and underfiller, as illustrated) to the FR4        substrate, having a thickness of approximately 100 μm    -   a glob top epoxy disposed over the chip and connections, having        a thickness with chip of approximately 160 μm    -   an antenna wire having ends connected to “connection pads”,        typically on the same side of the FR4 substrate as the RFID        chip, but can also be connected on the opposite side of the FR4        substrate as the chip.

The total thickness of the epoxy glass module may be 260 μm, such as foran inlay substrate having a thickness of approximately 365 μm.Generally, the chip module will be disposed in a recess in the inlaysubstrate so as to be concealed therein.

Generally speaking, epoxy glass modules are inherently somewhat moreflexible than leadframe modules. This is a factor that may need to betaken into consideration when incorporating an RFID module into a securedocument. And, whereas leadframe modules are typically rectangular, themold part (glob top) of an epoxy glass module are typically round.

It should be understood that, although FIG. 1D shows a flip chipconnection between the RFID chip and the FR4 substrate, the chip can bewire-bonded to the substrate (such as was shown in FIG. 1C, for theleadframe-type module.)

SOME DEFINITIONS AND TERMINOLOGY

An “inlay” or “inlay laminate” may comprise an “inlay substrate” whichis a planar sheet of plastic material, such as Teslin™. A “chip module”disposed in a “recess” in the inlay substrate. An antenna wire ismounted to the inlay substrate, such as be embedding (countersinking)within or adhesively attaching (sticking, placing) to a surface of theinlay substrate.

A chip module may include an RFID (radio frequency identification) chipand means such as a leadframe or an epoxy-glass (FR4) substrate forfacilitating interconnecting the RFID chip with an antenna. Some RFIDchips have integrated antennas, and do not require the means forinterconnecting with and antenna. As used herein “chip” and “chipmodule” can encompass many configurations of a silicon die or a packagedchip.

The antenna is typically in the form of a flat coil of wire having anumber (such as 4 or 5) of turns and two end portions which areconnected to corresponding contact pads (contact areas, terminals) ofthe chip module. The antenna may be a dipole antenna having two wiresegments with two inner ends, or any other antenna configurationsuitable for connection to a chip or chip module in an inlay. The wiremay include any elongate means for conveying or radiating signals, suchas metallic wire (such as gold, aluminum, copper, silver), of anyprofile (such as round or rectangular), either bare, coated or colorcoated, as well as optical fibers.

The recess for receiving the chip module extends into the inlaysubstrate from a “top” surface thereof, and may be a “window” typerecess extending completely through the inlay substrate to a “bottom”surface thereof, or the recess may be a “pocket” type recess extendingonly partially through the inlay substrate towards the bottom surfacethereof.

The recess may have a “straight” profile—in other words, substantiallyconstant cross-dimension through (or into) the inlay substrate. Or, therecess may have a “stepped” profile, including a larger cross-dimensionat the top surface of the substrate than at (or towards) the bottomsurface of the inlay substrate. The recess is generally sized and shapedto accommodate the size and shape of the chip module being disposedtherein. The term “cavity” may be used interchangeably with “recess”.

A secure document, such as an electronic passport (e-passport) comprisesan “inlay” (inlay substrate, plus chip module, plus antenna) and a“cover” layer (or substrate). The inlay plus cover constitute an“e-cover”. The “inlay” may be fully functional, but rarely would be usedon its own, without additional, protective layers (such as the coverlayer) laminated thereto.

The inlay substrate may comprise, for example, Teslin™, PVC,Polycarbonate (PC), polyethylene (PE) PET (doped PE), PETE (derivativeof PE), and the like.

The cover layer may comprise, for example, PVC, coated offset board,with or without optical bleacher or acrylic coated cotton, supplied inweb form or in sheets.

E-covers may be manufactured several at a time, such as “3up”, on an“inlay sheet” which may include several (a plurality of) distinct“transponder areas” (or “transponder sites”) on an “oversize” inlaysubstrate, for forming a plurality of e-covers. Each transponder sitemay comprise a chip module and antenna mounted to the inlay substrate.The chip module and antenna may be referred to as a “transponder”. Acover layer may be laminated (joined) thereto, then the individuale-covers may be separated from the inlay sheet.

An Inlay and Transponder of the Prior Art

FIGS. 1E and 1F illustrate an inlay sheet 100 having a plurality oftransponder areas (or sites). A selected one of the transponder areas102 is shown in detail. The vertical and horizontal dashed lines (inFIG. 1E) are intended to indicate that there may be additionaltransponder areas (and corresponding additional transponders) disposedto the left and right of, as well as above and below, the transponderarea 102, on the inlay sheet 100. As best viewed in FIG. 1F, the inlaysheet 100 may be a multi-layer substrate 104 comprising one or moreupper (top) layers 104 a and one or more lower (bottom) layers 104 b.

A recess 106 may be formed in (completely through) the upper layer 104 aso that a transponder chip 108 may be disposed in the recess 106, andsupported by the lower layer 104 b. The transponder chip 108 is shownhaving two terminals 108 a and 108 b on a top surface thereof.

This inlay sheet 100 is representative of a credit card, using hotlamination to bond the material. The overall thickness of the inlaysheet (104 a and 104 b) is approximately 450 μm.

-   -   the thickness of a top overlay layer (not shown), approximately        50 μm    -   the thickness of the top layer(s) 104 a, approximately 400 μm    -   depth of the recess 106, same as thickness of the top layer(s)        104 a    -   thickness of the transponder chip 108, approximately 320 μm    -   thickness of the bottom layer(s) 104 b, approximately 240 μm

Generally, the recess 106 is sized and shaped to accurately position thetransponder chip 108, having side dimensions only slightly larger thanthe transponder chip 108 to allow the transponder chip 108 to be locatedwithin the recess 106. For example,

-   -   the transponder chip 108 may measure: 5.0×8.0 mm    -   the recess 106 may measure: 5.1×8.1 mm    -   the terminals 108 a/b may measure: 5.0×1.45 mm    -   the wire (discussed below) may have a diameter between 60 and        112 μm

One millimeter (mm) equals one thousand (1000) micrometers (μm,“micron”).

In FIGS. 1E and 1F, the recess 106 may be illustrated with anexaggerated gap between its inside edges and the outside edges of thechip 108, for illustrative clarity. In reality, the gap may be onlyapproximately 50 μm-100 μm (0.05 mm-0.1 mm)

In FIG. 1E the terminals 108 a and 108 b are shown reduced in size(narrower in width), for illustrative clarity. (From the dimensionsgiven above, it is apparent that the terminals 108 a and 108 b canextend substantially the full width of the transponder chip 108.)

It should be understood that the transponder chip 108 is generallysnugly received within the recess 106, with dimensions suitable that thechip 108 does not move around after being located within the recess 106,in anticipation of the wire ends 110 a, 110 b being bonded to theterminals 108 a, 108 b.

As best viewed in FIG. 1E, an antenna wire 110 is disposed on a topsurface (side) of the substrate 104, and may be formed into a flat(generally planar) coil, having two end portions 110 a and 110 b.

As best viewed in FIG. 1F, the antenna wire 110 is “mounted” to thesubstrate 104 a, which may comprise “embedding” (countersinking) theantenna wire into the surface of the substrate, or “adhesively placing”(adhesively sticking) the antenna wire on the surface of the substrate.The wire typically feeds out of a capillary 116 of an ultrasonic wireguide tool (or “sonotrode”, not shown). The capillary 116 is typicallydisposed perpendicular to the surface of the substrate 100. Thecapillary 116 is omitted from the view in FIG. 1E, for illustrativeclarity.

The antenna wire 110 may be considered “heavy” wire (such as 60 μm) andrequires higher bonding loads than those used for “fine” wire (such as30 μm). Rectangular section copper ribbon (such as 60×30 μm) can be usedin place of round wire.

The capillary 116 may be vibrated by an ultrasonic vibration mechanism(not shown), so that it vibrates in the vertical or longitudinal (z)direction, such as for embedding the wire in the surface of thesubstrate, or in a horizontal or transverse (y) direction, such as foradhesively placing the wire on the surface of the substrate. In FIG. 1F,the wire 110 is shown slightly spaced (in drawing terminology,“exploded” away) from the substrate, rather than having been embedded(countersunk) in or adhesively placed (stuck to) on the surface of thesubstrate.

The antenna wire 110 may be mounted in the form of a flat coil, havingtwo ends portions 110 a and 110 b. The ends portions 110 a and 110 b ofthe antenna coil wire 110 are shown extending over (FIG. 1E) and maysubsequently be connected, such as by thermo-compression bonding (notshown), to the terminals 108 a and 108 b of the transponder chip 108,respectively.

Examples of embedding a wire in a substrate, in the form of a flat coil,and a tool for performing the embedding (and a discussion of bonding),may be found in U.S. Pat. No. 6,698,089 (refer, for example, to FIGS. 1,2, 4, 5, 12 and 13 of the patent). It is known that a coated,self-bonding wire will stick to a synthetic (e.g., plastic) substratebecause when vibrated sufficiently to soften (make sticky) the coatingand the substrate.

In FIG. 1F, the wire 110 is shown slightly spaced (in drawingterminology, “exploded” away) from the terminals 108 a/b of thetransponder chip 108, rather than having been bonded thereto, forillustrative clarity. In practice, this is generally thesituation—namely, the end portions of the wires span (or bridge), therecess slightly above the terminals to which they will be bonded, in asubsequent step. Also illustrated in FIG. 1F is a “generic” bond head,poised to move down (see arrow) onto the wire 110 b to bond it to theterminal 108 b. The bond head 118 is omitted from the view in FIG. 1E,for illustrative clarity.

The interconnection process can be inner lead bonding (diamond tool),thermo-compression bonding (thermode), ultrasonic bonding, laserbonding, soldering, ColdHeat soldering (Athalite) or conductive gluing.

As best viewed in FIG. 1E, due to the layout of the antenna coils, theantenna wire 110 needs to cross over itself. This is illustrated in thedashed-line circled area “c”. In order to prevent shorting (electricalcontact between different portions of the antenna coil) the antenna wireshould be an insulated wire, generally comprising a metallic core and aninsulation (typically a polymer) coating. Also, the polymer coatingfacilitates the wire being “adhesively placed” on (stuck to) a plasticsubstrate layer (such as 104 a). (In some cases, the antenna wire doesnot need to cross over itself. See, for example, FIG. 4 of U.S. Pat. No.6,698,089).

In order to feed the wire conductor back and forth through theultrasonic wire guide tool, a wire tension/push mechanism (not shown)can be used or by application of compressed air it is possible toregulate the forward and backward movement of the wire conductor byswitching the air flow on and off which produces a condition similar tothe Venturi effect.

By way of example, the wire conductor can be self-bonding copper wire orpartially coated self-bonding copper wire, enamel copper wire orpartially coated enamel wire, silver coated copper wire, un-insulatedwire, aluminum wire, doped copper wire or litz wire.

The inlay substrate 104 a may comprise PVC, PC, PE, PET, PETE, TYVEK,TESLIN, Paper or Cotton/Noil.

A cover layer (not shown) can be disposed over the inlay substrate 104 afor the final product, which may be an e-ID card. See. FIG. 1B.

The conventional method of embedding an insulated copper wire into asynthetic substrate is described in U.S. Pat. Nos. 6,233,818 and6,698,089 in which an ultrasonic converter is bolted to a sonotrodehaving a capillary hole to allow the passage of wire from the side ofthe sonotrode to the tip. The ultrasonic converter coaxially inducesvibrations into the sonotrode, thus creating localized friction and heatagainst the wire emerging from the tip of the sonotrode with a syntheticsubstrate. The wire is embedded into the substrate by inducingvibrations into the sonotrode and applying pressure, while at the sametime moving the complete assembly to route the wire into the substrateto create an antenna with several turns. Embedding wire into a syntheticsubstrate such as PVC with a soft texture and low melting point can beaccomplished using the conventional technique, but countersinking anantenna wire into a Teslin™ substrate, requires the additional procedureafter the wire embedding process of pre-pressing the Teslin™ inlay in alamination press.

Mounting an antenna wire to an inlay substrate by “embedding” or“adhesively attaching” have been mentioned, and are suitable forproducing inlay substrates of secure documents, such as electronicpassports. However, some of the techniques for producing electronicpassports discussed herein may also be applicable to inlay substrateswherein the antenna comprises traces on an etched PWB (printed wiringboard) or printed antenna (conductive ink) substrates. See, for example,U.S. Pat. Nos. 6,379,779; 6,406,935; 7,000,845; 7,449,212; and US PatentPublication Nos. 20090066076 and 20090115185, all of which areincorporated by reference herein.

An Example of Forming an Electronic Passport Cover (E-Cover)

The production of an electronic passport cover (such as shown FIG. 1A)in may involve the adhesive attachment of an inlay substrate with acover layer.

FIG. 1G is a plan view illustrating an “inlay”, (or “passport inlay”, or“e-cover inlay”) for preparing three (3) “passport covers” (such asshown in FIG. 1A). The cover layer 104 is shown partially, so as toreveal the underlying inlay substrate 108. FIG. 1H is a cross-sectionalview through FIG. 1G.

FIGS. 1G and 1H illustrate an e-cover inlay 100 having a “front” portionand a “back” portion, and comprising:

-   -   a cover layer (cover material) 104, such as approximately 350 μm        thick; and    -   an inlay substrate 108, such as approximately 356 μm thick (14        mils) Teslin™

The material for the cover layer 104 may be PVC coated offset board oracrylic coated cotton, embossed and thermo-resistant. In the case of thefabric material, the backside coating can be water-base coated(aqueous/non-solvent), synthetic coated or have no coating. The frontside coating can have two base coatings and one top coating of acrylic.An alternative to acrylic coating is peroxylene-based coating(nitrocellulose). The fabric can have a strong bias (diagonal) in theweave (drill weave as opposed to linear weave) which gives it hightensile strength and restricts the elongation. The leather embossinggrain can have the resemblance of the skin of a kid goat or sheep(skiver) and is applied using an embossing cylinder drum at a pressureof 60 tons at around 180 degrees Celsius (° C.). Because of the frontand backside coatings the fabric is not porous.

The material for the cover layer 104 may be a cloth product, withchemistry in the coatings and a leather-like appearance to the cloth,such as by Holliston Inc. (905 Holliston Mills Road, Church Hill, Tenn.37642; www.holliston.com)

The material for the inlay substrate 108 may be Teslin™, a waterproofsynthetic film, single-layer, uncoated with a thickness of 356 microns.

The material for the inlay substrate 108 may be PVC, PC, PE, PET, PETE,TYVEK, TESLIN, Paper or Cotton/Noil. The inlay substrate can also havespecial markings such as luminous threads, water marks, microscopicfilings and optical polymer memory for additional security.

The inlay format is typically “3up” (for making three passport covers atonce), and is generally planar and rectangular, having exemplary overalldimensions of 404.81 mm×182.56 mm×0.70 mm (thick). Each one of the threecovers (A), (B) and (C) are generally rectangular, having exemplarydimensions of (404.81 mm/3)=134.94 mm×182.56 mm, with a thickness of0.70 mm. In FIG. 1G, “A”, “B” and “C”, each are a “transponder site” fora given passport cover (see FIG. 1A).

The inlay substrate 108 is prepared with index slots, holes, windows forthe 3 chip modules' mold mass and hinge gaps for the passport covers,and is then cut into sheets. The approximate width of the Teslin™substrate is 248 mm, whilst the cover layer is approximately 216 mm witha Teslin™ margin of 14 mm one side and 18 mm on the other side(248=216+14+18).

A hinge gap 106 may be cut or punched through the inlay substrate 108and the cover layer 104, separating the “front” portion from the “back”portion of the passport cover(s).

An RFID chip module 110 and corresponding antenna wire 120 are disposedin the inlay substrate 108.

-   -   the chip module 110 may be a leadframe-type chip module (compare        FIG. 1C) comprising a chip encapsulated by a mold mass 112 and a        leadframe 118.    -   the mold mass may be approximately 240 μm thick and 5 mm wide    -   the leadframe 118 may be approximately 80 μm thick and 8 mm        wide.    -   the chip module 110 may have an overall size of 5.1×8.1 mm,        encapsulation size: 4.8×5.1 mm, leadframe thickness: 75 to 80 μm        and overall thickness of the module (leadframe and mold mass)        approximately 320 μm.    -   the antenna wire 120 may comprise 4 or 5 turns of wire, such as        approximately 80 μm diameter (thick) wire. Ends of the antenna        wire 120 are connected to the leadframe 118, such as described        with respect to FIG. 1C.

The inlay substrate 108 may be prepared by embedding an insulated wire(such as 80 μm) into the inlay substrate 108 to form an antenna 120 with4 turns and interconnecting the wire ends of the antenna to a leadframechip module by means of thermo-compression bonding.

The leadframe chip module 110 may include a mold mass, such as epoxy orresin, surrounding a silicon die on the leadframe 118. (see FIG. 1C)

The chip module 110 is disposed in a recess 116 in the inlay substrate.The recess 116 may be slightly wider than the module (compare FIG. 1F).The recess 116 may be a “stepped” recess, as shown, and may be a“window” recess extending completely through the inlay substrate 108.Normally, the opening of the recess 116 at the bottom of the inlaysubstrate 108 is left open, revealing the mold mass 112 (flush with thebottom surface), which presents security problems.

The recess 116 has a larger cross-dimension at the top surface of theinlay substrate 108 to accept the protruding leadframe 112 on each sideof the chip module, and this larger portion of the recess may be formedby using an ultrasonic stamp to create a dent (depression) into the topsurface of the inlay substrate 108.

A stepped recess, such as the recess 116 shown in FIG. 1H may be createdin a single layer by first forming a window opening through the layer,then compressing the layer (such as the inlay substrate 108) to form a“shoulder” (region of reduced cross-dimension) around a periphery of thewindow opening. See US 2009/0091424, incorporated by reference herein.

The cover layer 104 is laminated (joined) to the inlay substrate 104using a polyurethane hot melt adhesive 114, such as approximately 50-80μm thick. Prior to the adhesive process, the inlay substrate may bepre-pressed to ensure that the antenna wire does not protrude over(extend above) the surface of the Teslin™ substrate, in other words, toensure that the antenna wire is fully embedded in the inlay substrate.

Non-reactive adhesives based on polyamide are typically not used inelectronic passports for security reasons, as it would be possible tode-laminate the material by applying heat. Instead, reactive adhesive,moisture curing hot melt adhesive based on polyurethane, is used. Manyare available.

The adhesive can be characterized by a high initial tack and a long opentime (several minutes) or a short setting time (several seconds). In thelatter case, the adhesive has to be reactivated using infra red lightbefore the cover layer is attached to the inlay, or hot laminated withina certain period (within 1 to 2 hours). The adhesive cures exclusivelyin the presence of moisture and gains its final strength after 3 to 7days.

The adhesive may be applied to the cover layer (cover material) atapproximately 150 degrees Celsius, putting down a layer of 50 to 80microns (μm). The inlay is applied to the cover layer (cover material)in web or in sheet form, and is then laminated together using a rollpress. Thereafter, the laminated inlay with the cover layer (covermaterial) is cut to size and stored in a stack for 3 to 7 days in astorage area having a regulated temperature and humidity.

Some Technical (Physical) Problems Associated With Using Hot-MeltAdhesive

The technique of applying moisture-curing hot melt based on polyurethaneto a cover material processed in web form may have a number ofdrawbacks:

The back side of the cover material has a non-smooth (grained) texturewhich prevents a homogenous layer of adhesive coating being applied,irrespective of the coating applicator such as slot nozzle, screenprinting, spray applicator or flexo/gravure roller. In the event ofover-coating in a humid environment, leaving an uneven thickness ofadhesive on the cover layer, the probability of CO2 emission afterlamination is quite high. The release of CO2 gas from the adhesive layerresults in the formation of bubbles between the cover material and theTeslin inlay.

The tensile strength properties and the thermal expansion coefficient ofthe cover material differ significantly from that of Teslin™. During thecoating process in which adhesive is applied to the cover material atapproximately 150° Celsius and thereafter during the roll presslamination process to reactivate the adhesive at 125° Celsius, theTeslin™ inlay held at room temperature is positioned onto the covermaterial, meaning that the different thermal expansion of the substratescan lead to sideways displacement of the finished product. Thismechanical displacement results in the so-called “banana effect” inwhich the electronic passport cover is curve shaped (warped).

As the cover layer (cover material) in web form is stretched acrossdrums during the coating and lamination processes, the cover layer(cover material) memorizes the curved shape of the drums which canpresent a problem during curing. If the final product is stored instacks under the pressure of a weight, separated by paper sheets, in anon-controlled temperature and humidity environment, the optimal curingtime of 3 to 7 days will vary significantly according to productionbatches. The resulting effect of a short curing time is the warping ofthe final product.

Apart from the formation of bubbles and the warping of the finalproduct, the longevity of the electronic passport could be reduced bymoisture seeping into the exposed area around the mold mass of the chipmodule.

Some Security Concerns Regarding Secure Documents

Apart from the above “technical” issues (physical problems) whichimpinge on the quality, reliability and longevity of secure documents,there may be a number of additional concerns surrounding (i) securityand (ii) the type of chip module (such as leadframe module, or epoxyglass module) used, for example, in a passport inlay.

To prevent or indicate tampering of the area surrounding the chipmodule, it is advantageous to hide the transponder chip or chip moduleand the wire interconnections thereto in the inlay substrate layer toenhance protection against falsification. Security elements may also bedesigned in particular as optically variable elements, such asholograms, electroluminescent pigments, or interference layer elementsfor example which, when viewed, give different color impressionsdepending on the viewing angle.

One of the impediments in hiding the transponder chip module and thewire interconnections thereto in the inlay substrate layer (thickness:356 microns) has been the thickness of the chip module with 320 microns.In addition, metal leadframe chip modules mounted to an inlay substratetend to break during torsion and bending of the substrate. Semiconductorcompanies have reduced the footprint and thickness of the chip moduledown to 250 microns, by packaging the transponder chips as a flip-chipmodule, glass epoxy module, plastic leadframe module or as naked dieconnected directly to the wire ends of an antenna.

To prevent external skimming of the data stored in the transponder chipwhen a passport is closed, it is desired that an electromagnetic shieldbe integrated into the front and back cover of a passport cover. See,for example, US 2007/0205953 (Axalto), incorporated in its entirety byreference herein.

GLOSSARY & DEFINITIONS

Unless otherwise noted, or as may be evident from the context of theirusage, any terms, abbreviations, acronyms or scientific symbols andnotations used herein are to be given their ordinary meaning in thetechnical discipline to which the disclosure most nearly pertains. Thefollowing terms, abbreviations and acronyms may be used throughout thedescriptions presented herein and should generally be given thefollowing meaning unless contradicted or elaborated upon by otherdescriptions set forth herein. Some of the terms set forth below may beregistered Trademarks®).

-   Chip As used herein, the word “chip” can encompass many    configurations of a silicon die or a packaged chip. The silicon die    for example can have metallized bumps to facilitate the direct    connection of the wire ends of an antenna to form a transponder or    tag device. A package chip can include various structures such as a    tape automated bonding module, a chip module, a flip chip module, a    leadframe, a glass epoxy flexible module, a chip carrier, a strap,    an interposer or any form of packaging to facilitate transponder    manufacturing.-   Electronic Ink It is a proprietary material that is processed into a    film for integration into electronic displays. The principal    components of electronic ink are millions of tiny microcapsules.    Each microcapsule contains positively charged white particles and    negatively charged black particles suspended in a clear fluid. When    a negative electric field is applied, the white particles move to    the top of the microcapsule where they become visible to the user.    This makes the surface appear white at that spot. At the same time,    an opposite electric field pulls the black particles to the bottom    of the microcapsules where they are hidden. By reversing this    process, the black particles appear at the top of the capsule, which    now makes the surface appear dark at that spot. To form an E Ink    electronic display, the ink is printed onto a sheet of plastic film    that is laminated to a layer of circuitry. The circuitry forms a    pattern of pixels that can then be controlled by a display driver.    These microcapsules are suspended in a liquid “carrier medium”    allowing them to be printed using existing screen printing processes    onto virtually any surface, including glass, plastic, fabric and    even paper.-   Faraday Cage Faraday shield is an enclosure formed by conducting    material, or by a mesh of such material. Such an enclosure blocks    out external static electrical fields. Faraday cages are named after    the English scientist Michael Faraday, who invented them in 1836. A    Faraday cage's operation depends on the fact that an external static    electrical field will cause the electrical charges within the cage's    conducting material to redistribute themselves so as to cancel the    fields effects in the cage's interior. This phenomenon is used, for    example, to protect electronic equipment from lightning strikes and    other electrostatic discharges. To a large degree, Faraday cages    also shield the interior from external electromagnetic radiation if    the conductor is thick enough and any holes are significantly    smaller than the radiation's wavelength.-   FR-4 FR-4, an abbreviation for Flame Retardant 4, is a type of    material used for making a printed circuit board (PCB). It describes    the board substrate, with no copper layer. FR-4 meets the    requirements of Underwriters Laboratories UL94-V0. The FR-4 used in    PCBs is typically UV stabilized with a tetrafunctional epoxy resin    system. It is typically a transparent yellowish color—the green, red    and sometimes blue color of a finished board comes from the solder    mask. FR-4 manufactured strictly as an insulator (without copper    cladding) is typically a difunctional epoxy resin system and a    greenish color. FR-4 is similar to an older material called G-10.    G-10 lacked FR-4's self-extinguishing flammability-characteristics.    FR-4 has widely replaced G-10 in most applications. Some military    applications where destruction of the circuit board is a desirable    trait will still utilize G-10.-   Inlay An inlay substrate typically has a plurality, such as array of    transponder sites on a substrate which matches the position of the    data or graphics on a printed sheet or holder/cover page of a smart    card or electronic passport respectively.    -   A secure inlay is similar to a conventional inlay but with        additional features such as an additional RFID chip on the        transponder site storing information about the production        processes in the value chain as well as having personalization        features integrated into the inlay such as a hologram, an        anti-skimming material or security codes embedded into the        inlay.-   Laminating As used herein, in its most general sense, laminating    refers to joining two (or more) sheets of material to one another.    The sheets may be the same material as one another. Two different    (and distinct) kinds of lamination are discussed herein.    -   Hot Lamination which used temperature and pressure to cause the        two sheets of material to fuse with one another    -   Cold Lamination in which an adhesive is used to join the two        sheets of material to one another.-   Laser Ablation Laser ablation is the process of removing material    from a solid (or occasionally liquid) surface by irradiating it with    a laser beam. At low laser flux, the material is heated by the    absorbed laser energy and evaporates or sublimates. At high laser    flux, the material is typically converted to a plasma. Usually,    laser ablation refers to removing material with a pulsed laser, but    it is possible to ablate material with a continuous wave laser beam    if the laser intensity is high enough.    -   The depth over which the laser energy is absorbed, and thus the        amount of material removed by a single laser pulse, depends on        the material's optical properties and the laser wavelength.        Laser pulses can vary over a very wide range of duration        (milliseconds to femtoseconds) and fluxes, and can be precisely        controlled. This makes laser ablation very valuable for both        research and industrial applications.    -   The simplest application of laser ablation is to remove material        from a solid surface in a controlled fashion. Laser machining        and particularly laser drilling are examples; pulsed lasers can        drill extremely small, deep holes through very hard materials.        Very short laser pulses remove material so quickly that the        surrounding material absorbs very little heat, so laser drilling        can be done on delicate or heat-sensitive materials.    -   A typical laser for ablating synthetic material such as Teslin™        or Polycarbonate is an ultra violet diode pump laser operating        at the wavelength of 385 nm-   Metallic Pigments Metallic pigments such as aluminium pigments are    utilized in the coating-   Pigments industry to fulfil functional requirements such as    electrical conductivity and shielding in consumer electronics.    Typical metal pigments range from approximately 3 μm (offset    printing) to over 50 μm.-   Mold Mass Mold mass is the part of a chip module which encapsulates    the area surrounding a silicon die mounted on a leadframe or carrier    and the wire bond connections (Au wire Ø 24 μm) thereto. The mold    mass is typically epoxy duraplast and the encapsulation process is    transfer molding. Alternatively, the silicon die and wire    interconnections can be protected by dispensing a fast curing resin    (glob top).-   Patch A piece of material used to cover a hole, cavity or recess    area in a substrate layer assigned to a transponder chip and or    antenna, used to protect and hermetically seal the underlying chip    and interconnections thereto, to prevent moisture seeping into and    electro-static discharge (ESD) entering the assigned area, having    security elements which may overlap onto the substrate layer. The    patch may be attached to the substrate layer by means of adhesion,    lamination under pressure and temperature, laser welding, ultrasonic    collation, etc.-   Printed Silicon Electronics Printed Silicon Electronics refers to    semiconductor technology using printable silicon-based inks,    additive printing techniques and thin film technology. Silicon ink,    oxide inks and metal inks are deposited on thin metal-foil    substrates. After the ink is printed, it forms silicon islands that    are annealed to drive out the solvents, leaving a polysilicon    crystal film. Oxide inks are used to create a gate dielectric, other    inks for in situ n- and p-type dopants and metal inks for contacts    to the silicon.-   Reactive Adhesive In general, one-component moisture-curing    polyurethane hot-melt adhesive-based on reaction products from di-    or polyisocyanates and polyether-polyols, crystalline or partly    crystalline polyester-polyols and low molecular weight polymers from    olefinically unsaturated monomers and optionally hydroxylated    tackifying resins.-   RFID Short for “Radio Frequency Identification”. An RFID device    interacts, typically at a limited distance, with a “reader”, and may    be either “passive” (powered by the reader) or “active” (having its    own power source, such as a battery).-   Teslin A single layer of microporous, polyolefin-based, uncoated    film that bonds readily and firmly with toners, inks, adhesives and    laminating films. Teslin is a waterproof synthetic material that    works well with an inkjet printer, laser printer, or thermal    printer. Teslin is also single-layer, uncoated film, and extremely    strong. In fact, the strength of the lamination peel of a Teslin    sheet is 2-4 times stronger than other coated synthetic and coated    papers. Teslin comes in the sizes of 7 mil to 18 mil, though only    sizes 10 mil and 14 mil are sized at 8.5″ by 11″, for printing with    most consumer printers. Also available are perforated versions of    Teslin, specifically, 1up, 2up, 3up, 6up, and Sup. Teslin is used    widely in the production of drivers licenses, voter ID cards, and    other forms of identification card. Because of its commercial    availability, Teslin is also often found used for counterfeit or    fake IDs. “Teslin” is a registered trademark of PPG Industries, Inc.    for synthetic printing sheet.

SUMMARY OF THE INVENTION

It is a general object of the invention to provide improved techniquesfor use in the manufacture of security documents, and security documents(the “product”) having improved technical and security features. Forexample,

-   -   improvements in the manufacture of the product to reduce warpage        and breakage in the product, and to integrate and hide the chip        module and the wire interconnections in an inlay substrate layer        of the product and add security features to make alteration of        the product and/or the production of forgeries technically        impossible or at least uneconomical.    -   unauthorized separation of the cover material and inlay        substrate mechanically or through de-lamination should result in        the destruction of the chip module and the antenna    -   to prevent skimming of the personal data stored in the memory of        an RFID chip in an electronic passport by activating the secure        document with correct keys at close proximity or eavesdropping        by intercepting the communication between a reader and an        electronic passport, shielding is required.

Some features and embodiments disclosed herein may be concerned withtechniques to protect a chip module from moisture and mechanical shockusing a adhesive patch; to hide an antenna in a multi-layeredconstruction; to create recesses in a substrate to accommodate a chipmodule leadframe using laser ablation instead of compressing thematerial to form a recess; to loop the wire ends of an antenna adjacentto the terminals areas of a chip module in preparation forinterconnection, and to embed a wire conductor into a substrate using awire guide assembly consisting of an ultrasonic converter, aluminumblock directing the ultrasonic energy and a sonotrode.

Other features disclosed herein may be concerned with security issues:to hide a chip (die, leadframe chip module, epoxy glass chip carrier,etc) in a substrate using stepped recesses to accommodate the chip and apatch or patches to protect the chip and the wire interconnectionsthereto; to integrate security features into the inlay such as ahologram, metal security strip or an electronic ink display which can beactivated by the electro-magnetic field driving the RFID chip, and toshield a transponder unit in a passport cover from authorized skimmingwhen the passport cover is closed, by adding metallic pigments to theadhesive layer bonding the cover layer to the inlay substrate.

According to an embodiment of the invention, an inlay substrate for asecure document having a recess extending into the inlay substrate froma first (top) surface thereof for receiving a chip module therein, andan antenna wire disposed in the inlay substrate and connected with thechip module, the inlay substrate comprises: at least two layers of asynthetic material, such as Teslin™, laminated to one another with alayer of adhesive. The chip module may be a leadframe-type module or anepoxy glass type module.

The antenna wire may be disposed on a top one of the at least twolayers, or between the at least two layers.

The recess may be straight or stepped. The recess may be a pocket-typerecess extending only partially through the substrate or a window-typerecess extending completely through the inlay substrate. The recess maybe formed by laser ablation, or by freezing the material of the inlaysubstrate and machining (milling) it.

A moisture-resistant patch may cover the chip module. An epoxy fillingmay be disposed in the recess, surrounding the chip module and theantenna wire interconnections. A lid may covering an opening of therecess.

Channels may be formed (pre-formed) in a surface of the substrate withinwhich the antenna wire is at least partially embedded. The channels maybe formed by removing material or displacing material. The channels maybe formed by at least one of (i) laser ablation, (ii) gouging, (iii)ultrasonic stamp, and (iv) heating and molding.

The channels define a pattern for the antenna. An antenna wire may bemounted in the channel.

Rather than using antenna wire, the channels may be filled with aflowable, conductive material to form the antenna. Techniques aredisclosed for connecting the flowable, conductive material withterminals of a chip module.

Ferrite material may be incorporated into the inlay substrate to reflector absorb electromagnetic energy. Various embodiments are disclosed.

A cover layer may be laminated to the inlay substrate. The cover layerand inlay substrate may comprise an inlay, such as for a passportbooklet (cover) having a front panel and a back panel. Ashielding/detuning antenna may be disposed on the back panel of thepassport cover. A switch may be disposed in the passport cover fordisconnecting the chip module's antenna when the passport booklet isclosed.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference will be made in detail to embodiments of the disclosure,examples of which may be illustrated in the accompanying drawing figures(FIGs). The figures are intended to be illustrative, not limiting.Although the invention is generally described in the context of theseembodiments, it should be understood that it is not intended to limitthe invention to these particular embodiments.

Certain elements in selected ones of the figures may be illustratednot-to-scale, for illustrative clarity. The cross-sectional views, ifany, presented herein may be in the form of “slices”, or “near-sighted”cross-sectional views, omitting certain background lines which wouldotherwise be visible in a true cross-sectional view, for illustrativeclarity. In some cases, hidden lines may be drawn as dashed lines (thisis conventional), but in other cases they may be drawn as solid lines.

If shading or cross-hatching is used, it is intended to be of use indistinguishing one element from another (such as a cross-hatched elementfrom a neighboring un-shaded element). It should be understood that itis not intended to limit the disclosure due to shading or cross-hatchingin the drawing figures.

Elements of the figures may (or may not) be numbered as follows. Themost significant digits (hundreds) of the reference number correspond tothe figure number. For example, elements of FIG. 1 are typicallynumbered in the range of 100-199, and elements of FIG. 2 are typicallynumbered in the range of 200-299. Similar elements throughout thefigures may be referred to by similar reference numerals. For example,the element 199 in FIG. 1 may be similar (and possibly identical) to theelement 299 in FIG. 2. Throughout the figures, each of a plurality ofelements 199 may be referred to individually as 199 a, 199 b, 199 c,etc. Such relationships, if any, between similar elements in the same ordifferent figures will become apparent throughout the specification,including, if applicable, in the claims and abstract.

FIG. 1A is a perspective view of a security document which is a passportcover (e-cover), according to the prior art.

FIG. 1B is a perspective view of a security document which is anelectronic identification card (eID), according to the prior art.

FIG. 1C is a perspective view of a chip module which is a leadframemodule, according to the prior art.

FIG. 1D is a perspective view of a chip module which is an epoxy-glassmodule, according to the prior art.

FIG. 1E is a top view of a transponder site (one of many on an inlaysheet), according to the prior art.

FIG. 1F is a side, cross-sectional view, partially exploded, of a wirebeing mounted to the an inlay substrate and bonded to the terminals of atransponder chip, according to the prior art.

FIG. 1G is a top view of an inlay sheet for making e-covers, havingthree “transponder sites” (“3up”), according to the prior art.

FIG. 1H is a side, cross-sectional view, partially exploded, of ane-cover of FIG. 1G.

FIG. 2A is a cross-sectional view, illustrating a passport covercomprising a multi-layer inlay substrate and a patch covering a chipmodule in a recess of the inlay substrate, according to an embodiment ofthe invention.

FIG. 2B is a cross-sectional view, illustrating a passport covercomprising a multi-layer inlay substrate and a patch covering a chipmodule in a recess of the inlay substrate, according to an embodiment ofthe invention.

FIGS. 2C, 2D and 2E are cross-sectional views showing a method of makingthe passport cover in FIG. 2B, according to an embodiment of theinvention.

FIG. 2F is a cross-sectional view, illustrating a passport covercomprising a multi-layer inlay substrate and a patch covering a chipmodule in a recess of the inlay substrate, according to an embodiment ofthe invention.

FIG. 2G is a cross-sectional view, illustrating a passport covercomprising a multi-layer inlay substrate and a patch covering a chipmodule in a recess of the inlay substrate, according to an embodiment ofthe invention.

FIG. 2H is a cross-sectional view, illustrating a passport covercomprising a multi-layer inlay substrate and a chip module in apocket-type recess of the inlay substrate, according to an embodiment ofthe invention.

FIG. 2I is a cross-sectional view, illustrating a passport covercomprising a multi-layer inlay substrate and a chip module in apocket-type recess of the inlay substrate, according to an embodiment ofthe invention.

FIG. 2J is a cross-sectional view, illustrating a passport covercomprising a single layer inlay substrate and a chip module in apocket-type recess of the inlay substrate, according to an embodiment ofthe invention.

FIG. 3A is a perspective view illustrating a technique for forming arecess in an inlay substrate using laser ablation, according to anembodiment of the invention.

FIG. 3B is a cross-sectional view illustrating a technique for forming arecess in an inlay substrate using laser ablation, according to anembodiment of the invention.

FIG. 3C is a cross-sectional view illustrating a technique for forming arecess in an inlay substrate using laser ablation, according to anembodiment of the invention.

FIG. 3D is a cross-sectional view illustrating a technique for forming arecess in an inlay substrate using laser ablation, according to anembodiment of the invention.

FIG. 4A is a cross-sectional view illustrating a technique for creatingchannels for mounting an antenna wire in an inlay substrate, accordingto an embodiment of the invention.

FIG. 4B is a cross-sectional view illustrating a technique for creatingchannels for mounting an antenna wire in an inlay substrate, accordingto an embodiment of the invention.

FIG. 4C is a cross-sectional view illustrating a technique for creatingchannels for mounting an antenna wire in an inlay substrate, accordingto an embodiment of the invention.

FIG. 4D is a perspective view illustrating a technique for creatingchannels for mounting an antenna wire in an inlay substrate, accordingto an embodiment of the invention.

FIG. 4E is a cross-sectional view illustrating mounting an antenna wirein a channel, according to an embodiment of the invention.

FIG. 4F is a cross-sectional view illustrating an antenna wire mountedin a channel, according to an embodiment of the invention.

FIG. 4G is a cross-sectional view illustrating mounting an antenna wirein a channel, according to an embodiment of the invention.

FIG. 4H is a cross-sectional view illustrating an antenna wire mountedin a channel, according to an embodiment of the invention.

FIG. 4I is a cross-sectional view illustrating a flowable, conductivematerial being applied on a surface of a substrate to fill a channel,according to an embodiment of the invention.

FIG. 4J is a cross-sectional view illustrating a further step in thetechnique of applying a flowable, conductive material on a surface of asubstrate to fill a channel, according to an embodiment of theinvention.

FIG. 4K is a cross-sectional view illustrating a flowable, conductivematerial being applied to fill a channel in a layer of adhesive,according to an embodiment of the invention.

FIG. 4L is a cross-sectional view illustrating a further step in thetechnique of applying a flowable, conductive material to an adhesivelayer to fill a channel, according to an embodiment of the invention.

FIG. 4M is a top of an inlay substrate with recess for a leadframe-typechip module and channels for a flowable, conductive material, accordingto an embodiment of the invention.

FIG. 4N is a cross-sectional view illustrating a flowable, conductivematerial in channels formed in a surface of a substrate, and connectingthe conductive material to terminals of a chip module, according to anembodiment of the invention.

FIG. 4P is a cross-sectional view illustrating a further step in thetechnique of connecting a flowable, conductive material in channelsformed in a surface of a substrate with terminals of a chip module,according to an embodiment of the invention.

FIG. 4Q is a cross-sectional view of a technique for connecting aflowable, conductive material in channels formed in a surface of asubstrate with terminals of a chip module, according to an embodiment ofthe invention.

FIG. 5A is a top of an inlay substrate with recess for a leadframe-typechip module and channels for antenna wire, according to an embodiment ofthe invention.

FIG. 5B is a side, cross-sectional view of the inlay substrate of FIG.5B, showing embedding an antenna wire in the channel, and bonding endportions of the antenna wire to terminals of the chip module, accordingto an embodiment of the invention.

FIG. 5C is a top of an inlay substrate with recess for an epoxy glasstype chip module and channels for antenna wire, according to anembodiment of the invention.

FIG. 5D is a side, cross-sectional view of the inlay substrate of FIG.5C, showing embedding an antenna wire in the channel, and bonding endportions of the antenna wire to terminals of the chip module, accordingto an embodiment of the invention.

FIG. 6A is a cross-sectional view, illustrating an inlay substrate witha pocket-type recess, and a patch (lid) covering an opening of therecess, according to an embodiment of the invention.

FIG. 6B is a cross-sectional view, illustrating an inlay substrate witha window-type recess, and patches (lids) covering openings in the topand bottom of the recess, according to an embodiment of the invention.

FIG. 7A is a top view of a security feature which may be used in anembodiment of the invention.

FIG. 7B is a top view of a the security feature of FIG. 7A.

FIG. 7C is a perspective view of a security feature which may be used inan embodiment of the invention.

FIG. 7D is a cross-sectional view of a security feature which may beused in an embodiment of the invention.

FIG. 7E is a top view of a security feature which may be used in anembodiment of the invention.

FIG. 7F is a diagrammatic cross-sectional view of a security featurewhich may be used in an embodiment of the invention.

FIG. 8A is a cross-sectional view of a coated wire which may be usedwith embodiments of the invention.

FIG. 8B is a cross-sectional view of a using a laser to removeinsulation from a coated wire, a feature which may be used withembodiments of the invention.

FIG. 8C is a cross-sectional view of a security feature which may beused with embodiments of the invention.

FIG. 8D is a cross-sectional view showing a technique for directconnection of the antenna wire to an RFID chip, according to anembodiment of the invention.

FIG. 8E is a perspective view related to the technique for directconnection, according to an embodiment of the invention.

FIG. 8F is a plan view of a feature of an embodiment of the invention.

FIG. 9A is a cross-sectional view showing an embodiment of incorporatingferrite material into the inlay substrate, according to an embodiment ofthe invention.

FIG. 9B is a cross-sectional view showing an embodiment of incorporatingferrite material into the inlay substrate, according to an embodiment ofthe invention.

FIG. 9C is a cross-sectional view showing an embodiment of incorporatingferrite material into the inlay substrate, according to an embodiment ofthe invention.

FIG. 9D is a cross-sectional view showing an embodiment of incorporatingferrite material into the inlay substrate, according to an embodiment ofthe invention.

FIG. 9E is a cross-sectional view showing an embodiment of incorporatingferrite material into the inlay substrate, according to an embodiment ofthe invention.

FIG. 10A is a side view of a sonotrode of the prior art (such as in U.S.Pat. No. 6,698,089).

FIG. 10B is a cross-sectional view of an ultrasonic wire guide(embedding) tool, according to an embodiment of the invention.

FIG. 10C is a perspective view of the ultrasonic wire guide tool shownin FIG. 9B.

DETAILED DESCRIPTION

Various “embodiments” of the invention (or inventions) will bediscussed. An embodiment is an example or implementation of one or moreaspects of the invention(s). Although various features of theinvention(s) may be described in the context of a single embodiment, thefeatures may also be provided separately or in any suitable combination.Conversely, although the invention(s) may be described herein in thecontext of separate embodiments for clarity, the invention(s) may alsobe implemented in a single embodiment.

The relationship(s) between different elements in the figures may bereferred to by how they appear and are placed in the drawings, such as“top”, “bottom”, “left”, “right”, “above”, “below”, and the like. Itshould be understood that the phraseology and terminology employedherein is not to be construed as limiting, and is for descriptivepurposes only.

The invention relates generally to inlays and techniques for making theinlays, including technical features and security features. As usedherein, an “inlay” may be a single- or multi-layer substrate containingHF (high frequency) and/or UHF (ultra-high frequency) radio frequencyidentification (RFID, transponder) chips and/or modules. These inlaysmay be used in secure documents, such as, but not limited to, electronicpassports (ePassports) and electronic ID (eID) cards.

Some Embodiments of the Invention

Various embodiments of the invention will be presented to illustrate theteachings of the invention(s). In the main, examples of electronicpassport covers with inlay substrates having leadframe modules may beused to illustrate the embodiments. It should be understood that variousembodiments of the invention(s) may also be applicable to other securedocuments containing electronics (such as RFID and antenna), such aselectronic ID cards. Secure documents may also be referred to as“electronic documents”. In the main hereinafter, secure documents whichare passport inlays, typically cold laminated (with adhesive), arediscussed.

The following embodiments and aspects thereof may be described andillustrated in conjunction with systems, tools and methods which aremeant to be exemplary and illustrative, not limiting in scope. Specificconfigurations and details may be set forth in order to provide anunderstanding of the invention. However, it should be apparent to oneskilled in the art that the invention(s) may be practiced without someof the specific details being presented herein. Furthermore, well-knownfeatures may be omitted or simplified in order not to obscure thedescriptions of the invention(s).

A Multi-Layer Inlay Substrate, and a Patch (FIGS. 2A, 2B)

FIGS. 2A and 2B illustrate embodiments of a secure document which is aninlay 200 suitable for use as a passport cover. The inlay 200 comprisesa multiple-layer inlay substrate 208 and a cover layer 204 coldlaminated (adhesively attached, joined) to the inlay substrate 208 witha layer 214 of adhesive such as 50 μm, which may be applied by rollercoater.

A hinge gap 206 is shown in FIG. 2A (and in other figures). The hingegap 206 may simply be a gap, approximately 1 mm wide, between a left (asviewed) portion of the inlay substrate 208 and a right (as viewed)portion of the inlay substrate 208. The left portion of the inlay 200corresponds to the front of the passport cover (FIG. 1A), and the rightportion of the inlay 200 corresponds to the back portion of the passportcover (FIG. 1A).

Notice that, in FIG. 1G, the hinge gaps 106 do not completely separatethe back portion of the inlay substrate from the front portion, they arestill joined by a “web”. Typically, the gap is punched or cut afteradhesive coating and pre-press lamination (to smooth the surface)

The cover layer 204 is generally a planar sheet or layer of flexible,durable, often “textile-type” material, such as PVC, coated offsetboard, with or without optical bleacher or acrylic coated cotton.

The inlay substrate 208 (both layers 208 a and 208 b) is generally aplanar layer or sheet of flexible, durable, typically “plastic-type”material, such as Teslin™, PVC, Polycarbonate (PC), polyethylene (PE)PET (doped PE), PETE (derivative of PE), and the like. The material ofthe inlay substrate may be referred to as “synthetic paper”.

The inlay substrate, or a bottom layer thereof (particularly when theantenna is embedded on a top surface of the top layer), can also beconductive, such as a ferrite-coated or ferrite-containing substrate toreflect or absorb electromagnetic energy. This is indicated by theparticles (dots) in the bottom inlay substrate layer 208 b of FIG. 2A.

FIG. 9A (compare FIG. 2A) illustrates a multi-layer inlay substrate 908(compare 208). The inlay substrate 908 comprises an upper layer 908 a(compare 208 a) laminated with an adhesive 909 (compare 209) to a lowerlayer 908 b (compare 208 b). A cover layer 904 (compare 204) may belaminated with an adhesive 914 (compare 214) to the inlay substrate 908.

A ferrite layer (dots) can be created in a synthetic substrate layer 908b beneath the layer 908 a in which the antenna wire 920 (or conductivematerial forming an antenna) is located, being applicable to all typesof antennae such as wire embedded, etched or conductive ink antennae.

FIG. 9B illustrates that the inlay substrate layer 908 a in which theantenna wire 920 is embedded may be a ferrite-coated synthetic layer(having a ferrite coating 908 c). Since the antenna wire 920 is embeddedin the ferrite-containing material, a coated (insulated) antenna wire,such as shown in FIG. 8A should be used. See, for example, FlexieldSeries Flexible Composite-Type Electromagnetic Shield Materials For13.56 MHz RFID System, TDK Corporation, Tokyo Japan, incorporated byreference herein. See also U.S. Pat. No. 4,539,433, incorporated byreference herein. For a multi-layer inlay substrate, this could be thetop layer (208 a).

FIG. 9C illustrates that a recess (or cavity) may be created bymechanically milling or laser ablating a layer of the inlay substrate,then filling the recess with ferrite material (metal or nano-metalparticles) and conductive polymers, to create a 3D ferrite-structuredlayer. Here, the lower layer 908 b is provided with the recess 925 whichis filled with ferrite particles. The recess 925 may extend completelythrough the layer 908 b, or only partially through the layer 908 b.After the ferrite filling is cured, the area may be sealed with a patch(not shown) of synthetic material.

The ferrite material can be applied using digital non-impact inkjetprinting, conventional printing (flexography, gravure, screen printing,offset) or dispensing. The area of the ferrite layer is larger than thearea occupied by the antenna, in order to ensure optimal reflection ofthe electromagnetic energy.

FIG. 9D illustrates that the recess to accommodate the ferrite materialcan also be produced by using multiple layers with a cavity or cavitiesin the center substrate layer or layers. Only the bottom layer 908 b isshown, for illustrative clarity.

Here, the bottom layer 908 b comprises a sandwich construction of a toplayer 927 a, a middle layer 927 b and a bottom layer 927 c. The middlelayer 927 b has a window-type recess 927 extending completelytherethrough, and filled with ferrite material.

FIG. 9E (compare FIG. 9C) illustrates that the ferrite material may bedisposed in a recess 929, such as in the top layer 908 a, and after theferrite filling is cured, the area may be sealed with a patch 930 ofsynthetic material. The antenna wire 220 can also be embedded into thesame layer as the ferrite material and routed across the sealed patch930 to form the antenna pattern.

Returning to FIGS. 2A and 2B, an antenna wire 220 is mounted to a topsurface of the inlay substrate 208, and a chip module 210 is disposed ina recess 216 extending into the inlay substrate 208 from a top surfacethereof. The antenna wire 220 may comprise 4 or 5 turns of wire, such asapproximately 80 μm diameter (thick) wire. Ends of the antenna wire 220are connected to terminals of the chip module 210.

The recess 216 may be a window-type recess extending completely throughthe inlay substrate 208 to the bottom surface thereof. of the inlaysubstrate.

The chip module 210 may be a leadframe-type chip module comprising achip mounted on a leadframe 218 and encapsulated by a mold mass 212. Theleadframe 218 may be approximately 80 μm thick and 8 mm wide. The moldmass 212 may be approximately 240 μm thick and 5 mm wide. The chipmodule 210 may have an overall size (width dimensions) of 5.1×8.1 mm andan overall thickness of 320 μm. The width of the recess 216 should besufficient to accommodate the chip module (including leadframe 218),with some clearance.

The inlay substrate 208 comprises two or more layers 208 a and 208 bwhich are laminated (adhesively attached, joined) one another with alayer (or layers) 209 of adhesive such as 50-80 μm, which may be appliedby a roller coater. In the main hereinafter, a two-layer example of aninlay substrate 208 will be described, comprising an upper (topmost)layer 208 a and a lower (bottommost) layer 208 b.

The recess 216 for the chip module 210 extends into the inlay substrate208 from the top surface of the topmost layer 208 a, through the topmostlayer 208 a, and at least partially into the bottommost layer 208 b. Therecess 216 extends fully through the entire inlay substrate 208,including fully through the bottommost layer 208 a, exiting the inlaysubstrate 208 at the bottom of the bottommost layer 208 b.

The recess 216 is “stepped” in that it has a larger width dimensionopening at the top surface of the inlay substrate 208 than at the bottomsurface of the inlay substrate 208. For example, a top portion of therecess 216, for accommodating the leadframe 218 has a width dimension of5.3×8.1 mm, and a bottom portion of the recess 216 for accommodating themold mass 212 has a width dimension of 5.1×5.1 mm.

The stepped recess 216 may be formed by a first opening having a firstwidth dimension in the topmost layer 208 a, second opening having asecond width dimension in the next adjacent (which is the bottommost)layer 208 b. When the layers 208 a and 208 b are assembled with oneanother, the openings in the layers 208 a and 208 b are aligned (such asconcentric) with one another. The first width dimension is differentthan the second width dimension. The first width dimension, foraccommodating the leadframe, is shown greater than the second widthdimension, for accommodating the mold mass.

The openings of the recess 216 in the layers 208 a and 208 b may be anyappropriate shape, such as rectangular for a rectangular chip module orcircular for a circular (round) chip module. The openings may be formedby a mechanical punch operation.

In the prior art (FIG. 1H), a stepped recess may be formed in a singlelayer inlay substrate 108. by compressing the substrate using anultrasonic stamp. An advantage of forming the inlay substrate 208 with(at least) two layers 208 a and 208 b is that the stepped recess may beformed more easily, and precisely.

The chip module 210 disposed in the recess 216 in such a way that theleadframe 218 is nearly flush with the upper surface of the topsubstrate layer 208 a and the mold mass of the chip module is nearlyflush with a bottom side of the bottom substrate layer 208 b. However,note that the end portions of the antenna wire 220 are connected(bonded) to the top surface of the leadframe 218 (opposite the chip andmold mass which are on the bottom surface of the leadframe 218. Alsonote that the diameter of the antenna wire 220 is decreased where it isbonded to the leadframe 218. For example, the 80μm wire may becompressed to approximately 40μm during thermo-compression bonding.

In the finished inlay substrate 208, which may be considered an “interimproduct”, all of the components (chip module 210 and antenna 220)mounted in or to the inlay substrate 208 should not project beyond thesurface of the inlay substrate 208.

In FIG. 2A, the antenna wire 220 is embedded (disposed) in a top surfaceof the topmost substrate layer 208 a, and is connected with a topsurface of the leadframe 218.

In FIG. 2B, the antenna wire is embedded between the two adjacent inlaysubstrate layers 208 a and 208 b, such as in a top surface of the bottomsubstrate layer 208 b, or in the bottom surface of the top substratelayer 208 a.

FIG. 2B differs from FIG. 2A in that the antenna wire (which may beself-bonding wire) is disposed between the two substrate layers 208 aand 208 b (rather than atop the top layer 208 a). This may beaccomplished by:

-   -   first, with the top layer 208 a inverted (bottom side up),        partially embedding the antenna wire 220 into the bottom surface        of the top layer 208 a, without countersinking the antenna wire        220 entirely, leaving the antenna wire 220 to protrude above the        layer. For example, the antenna wire 220 is embedded only        approximately 30-70% of its diameter into the bottom surface of        the top layer 208 a, leaving 70-30% protruding above the bottom        surface of the top layer 208 a. Or, the antenna wire 220 is        embedded only approximately 40% or 50% of its diameter into the        bottom surface of the top layer 208 a leaving 60% or 50%,        respectively, protruding above the bottom surface of the top        layer 208 a. See FIG. 2C.    -   then, in a second step, the top layer 208 a is flipped over (top        side up), and is adhesively attached to the bottom layer 208 b        carrying the antenna, whereby the protruding antenna wire 220 is        positioned face down onto the top surface of the bottom layer        208 b, before lamination. In the lamination process, the antenna        wire 220 sinks into the bottom layer 208 b. The lamination        process has also the advantage of “disguising” the position of        the antenna in the two layered inlay substrate structure and        creating a smooth and even surface on each external surface (top        surface of the top layer, bottom surface of the bottom layer) of        the multi-layered inlay substrate structure. See FIGS. 2D and        2E.    -   Another feature of FIG. 2B is the wire ends of the antenna are        connected to the face-down side of the chip module leadframe.    -   An advantage of this inlay construction is that any attempt to        peel the two layers apart, results in the destruction of the        antenna and the wire interconnections to the chip module.

The chip module may be mounted face-down into the first layer 208 a,then the antenna 208 is scribed into the opposite side of the firstlayer 208 a, and the wire ends are connected to the chip module 210.

During the lamination process, the adhesive 209 compresses, somesqueezes out, and some may get absorbed into the cover layer during thelamination process. After lamination, the adhesive layer 209 may be only20 μm thick. The layers 208 a and 208 b may be “pre-pressed” with a hotlaminator to smooth the surface and hide the wires.

During embedding of the antenna wire, the wires “mark” the inlaysubstrate. The material may be flattened by putting the inlay substratesthrough temperature and pressure for about 30 minutes.

A security feature of the antenna wire location (between the two layers)shown in FIG. 2B is that if an attempt is made to pull the chip moduleout of the inlay, this may destroy the interconnections and wireantenna.

It should be understood that there are various “combinations” of moduleorientation and interconnection location which may be shown in FIGS. 2A& 2B, 2F & 2G, 2H, 2I & 2J, 5B, 5G, 6A & 6B. Generally, the module canbe mounted face down or face up and the interconnections thereto can beon the top of the module such as is the case with a leadframe orunderneath the chip carrier (epoxy glass or leadframe).

FIGS. 2C, 2D and 2E show a method of making the inlay substrate 208 ofFIG. 2B.

-   -   (FIG. 2C) with the top layer 208 a inverted (or, invert the top        layer 208 a), so the bottom surface is facing up, partially        embed the antenna wire 220 in the upward-facing bottom surface        of the top layer 208 a, leaving a portion of the (diameter of)        the antenna wire protruding from the surface;    -   (FIG. 2D) flip over (un-invert) the top layer 208 a so that its        bottom surface is facing downwards (and top surface is facing        upwards).    -   (FIG. 2E) laminate (with adhesive) the top layer 208 a (which        has the antenna wire protruding from the surface) to the bottom        layer 208 b, thereby embedding the protruding portion of the        antenna wire 220 into the top surface of the bottom layer 208 b.

Alternatively, the antenna wire 220 can first be partially embedded inthe top surface of the bottom layer 208 b, then in the laminationprocess, sunk into the bottom surface of the top layer 208 a.

Alternatively, the antenna wire 220 can be positioned between twoadjacent layers of the inlay substrate, then partially embedded intoboth layers, adhesively bonded and then laminated to form one cohesiveelectronic laminate layer. Any attempt to separate the two layers mayresult in the destruction of the antenna and the wire-end connections tothe chip module.

Some additional exemplary dimensions for the inlay 200 are:

-   -   overall thickness of the inlay 200, approximately 700 μm (0.700        mm), including cover layer 204 and adhesive layers 214 and 209    -   thickness of the cover layer 204, approximately 300 μm    -   thickness of the inlay substrate 208, approximately 356 μm    -   thickness of each layer 208 a and 208 b of the inlay substrate        208, approximately 145 μm    -   thickness of the adhesive 209 joining the two inlay substrate        layers 208 a and 208 b, approximately 50 μm    -   thickness of the adhesive 214 joining the cover layer 204 to the        topmost layer 208 of the inlay substrate 208, approximately 50        μm

FIG. 2B also illustrates a “deep trench” formed extending from thebottom surface of the top layer, to within the top layer 208 a, forrouting the antenna wire 220 to the chip module 510. The formation of“channels” and “deep trenches” is discussed in greater detailhereinbelow, such as with respect to FIGS. 4A and 5D

An additional feature shown in FIGS. 2A and 2B is a patch 230 covering(overlying) the chip module 210 and connections with the antenna wire220. For example, the patch 230 may be made of the same material as thesubstrate (such as Teslin™)—laminated, adhesively attaches, ultrasonicor laser welding—50 μm thick. This patch 230 is not exclusive to theinlay substrate 208, rather it could be used, for example, with theinlay substrate 108 of FIG. 1H.

In situations where the recess 216 extends completely through the inlaysubstrate 208, the patch 230 may seal the area of the chip module 210from moisture. The patch 230 may be moisture-resistant.

The patch 230 can be antistatic, to protect the chip module fromelectrostatic discharge.

The patch 230 may comprise a material that is luminous under ultraviolet(UV) light, so that tampering with the patch can be exposed bypresenting the inlay 208 to an ultraviolet light source. As is known,

-   -   To help thwart counterfeiters, sensitive documents (e.g. credit        cards, driver's licenses, passports) may also include a UV        watermark that can only be seen when viewed under a UV-emitting        light. Passports issued by most countries usually contain UV        sensitive inks and security threads. Visa stamps and stickers on        passports of visitors contain large and detailed seals invisible        to the naked eye under normal lights, but strongly visible under        UV illumination. Passports issued by many nations have UV        sensitive watermarks on all pages of the passport. Currencies of        various countries' banknotes have an image, as well as many        multicolored fibers, that are visible only under ultraviolet        (UV) light.

FIGS. 2F and 2G illustrate embodiments of a secure document which is aninlay 200 suitable for use as a passport cover. A cover layer 204 islaminated with adhesive 214 to a multi-layer inlay substrate 208comprising at least two layers 208 a and 208 b′ (prime), laminated withan adhesive 209 to one another. A chip module 210 comprising a chip (notshown), a leadframe 218 and a mold mass 212 is disposed in a recess 216extending into the inlay substrate 208 from a top surface thereof, andthe recess 216 is stepped.

FIG. 2F illustrates an embodiment of a secure document which is an inlay200 suitable for use as a passport cover. This inlay is substantiallythe same as the inlay 200 shown in FIG. 2A (multi-layer inlay substrate208, antenna wire 220 on top of top inlay substrate layer 208 a), withthe addition of a strip (or stripe) 232 of a material, such as metal orMylar, having a thickness of approximately 10 μm applied around the areawhere the patch 230 and the inlay substrate 208 (the bottom of thebottom inlay layer 208 b) meet, bridging any gap between the bottom ofthe patch 230 and the bottom of the inlay substrate 208. The stripe 232crosses any void between the patch 230 and the bottom surface of theinlay substrate 208.

FIG. 2G illustrates an embodiment of a secure document which is an inlay200 suitable for use as a passport cover. This inlay is substantiallythe same as the inlay 200 shown in FIG. 2B (multi-layer inlay substrate208, antenna wire 220 between the two substrate layers 208 a and 208 b).However, rather than using a patch (230), an epoxy filling 234, whichmay be luminescent under UV light, may be disposed in the recess,surrounding the chip module and the antenna wire interconnections. Thismay provide evidence of tampering when exposed to an ultraviolet lightsource.

FIGS. 2H and 2I show “variations” of inlays shown in FIGS. 2A and 2B. Inmost respects, the inlays 200′ (prime) of FIGS. 2E and 2F are similar tothe inlays 200 of FIGS. 2A and 2B. A cover layer 204 is laminated withadhesive 214 to a multi-layer inlay substrate 208 comprising at leasttwo layers 208 a and 208 b′ (prime), laminated with an adhesive 209 toone another. A chip module 210 comprising a chip (not shown), aleadframe 218 and a mold mass 212 is disposed in a recess 216 extendinginto the inlay substrate 208 from a top surface thereof, and the recess216 is stepped.

In FIG. 2H, in a manner similar to that shown in FIG. 2A, the antennawire 220 extends along (within) the top surface of the top layer 208 a,and connects to the top surface of the leadframe 218.

In FIG. 2I, in a manner similar to that shown in FIG. 2B, the antennawire 220 is disposed between the top layer 208 a and the bottom layer208 b, and connects to the bottom surface of the leadframe 218.

A feature shown in the embodiments of FIGS. 2H and 2I (and 2J), is thatrather than the recess 216 being a “window-type” recess extendingcompletely through the inlay substrate 208′ (prime), the recess 216′(prime) is a “pocket-type” recess extending only partially through theinlay substrate 208′. In the embodiments of FIGS. 2H and 2I, the recess216′ stops short of the bottom surface of the bottom layer 208 b′,leaving (for example) approximately 10 μm of material 208 c directlyunder the chip module 210. This essentially eliminates the need for thepatch 230 (FIGS. 2A, 2B), since there is no opening at the bottomsurface of the inlay substrate 208′ caused by the recess 216′.

At “first glance” it may appear that the multi-layer inlay substrate 208is not significantly different than the “one or more” top layers 104 aof the inlay sheet 100 shown in FIG. 1F. However, there are a number ofsignificant differences, such as:

-   -   the layers of a credit card (including, if applicable, multiple        layers of the inlay substrate) are hot laminated to one another    -   the layers of the passport booklet, such as the cover layer and        the inlay layer (including, if applicable, multiple layers of        the inlay substrate) are cold laminated to one another, with        adhesives.    -   the credit card is much thicker, making it easier to conceal and        protect the RFID chip    -   the antenna wire is embedded in a different plane    -   the layers of the inlay substrate 208 are adhesively attached to        one another, attempts to separate the two layers is intended to        result in the destruction of the chip module and the antenna.        This is an important security feature.    -   The standard construction of a multi-layered inlay (such as        suggested by the “one or more” top layers 104 a) is to hot        laminate the substrate together. There is no adhesive layer        (209). This is generally not possible with a synthetic paper        material like Teslin™.    -   1E and 1F are standard contactless card. 1F, if complete would        have another layer on top 0.78 mm (For ID cards, this is        important, as they all follow the ISO 7816 standard for        dimensions.)    -   in a passport, the material of cover layer is different than        material of inlay substrate    -   in the contactless card (FIG. 1F) the cover layer (not shown)        would be of the same material as the layer 104.    -   The thickness of a credit card (FIG. 1F) is sufficient to cover        and protect the chip and antenna. For example, 450 μm    -   With a passport (FIGS. 2A-2I), the chip module is approximately        as thick as the inlay substrate (both are in the range of        300-400 μm). It is more difficult to protect the chip module 210        in the passport than in the credit card. (A credit card 450 μm        thick, and the chip module is surrounded by the substrate layer.        In the passport, the substrate does not cover the chip,        entirely.)

In the embodiments described above, with respect to FIGS. 2A-2I, theinlay substrate layers (such as Teslin™) are adhesively attached to formthe inlay substrate 208 integrating the transponder (chip module 210) inthe center of the inlay 200. Any attempt to separate the two layers (208a, 208 b) should result in the destruction of the inlay 200. Also thepatch 230 protects the chip module 210.

FIG. 2J shows another variation on the inlay 200″ (double prime). Again,most of the elements are the same as for the inlays 200 and 200′, andthe inlay 200″ is nearly identical to the inlay 200′. A cover layer 204is laminated to the inlay substrate 208, an antenna 220 is mounted tothe inlay substrate 208, and a chip module 210 is disposed in a stepped,pocket-type recess 216′. However, here, the inlay substrate 208″ (doubleprime) is formed in a single layer inlay substrate 208″.

Fabricating the Inlay (Passport Cover)

Various methods may be used to fabricate the passport cover (200) suchas:

-   -   The first and second layers (208 a and 208 b) of the inlay        substrate (208) may be adhesively attached to one another in        sheet (rather than roll) format.    -   The cover material (204) may also be processed in sheet format        by applying a layer of polyurethane hot melt adhesive with a        short opening time using a roller coating machine.    -   The adhesive-coated cover material (204) may be positioned on        the multi-layered inlay substrate and affixed at two (or more)        points using an ultrasonic collator.    -   The inlay substrate (208) may then be laminated to the cover        material (204) by reactivating the polyurethane hot melt        adhesive in a hot roll or lamination press.    -   Instead of applying heat to the cover material, it can be        advantageous to apply the heat to the inlay substrate at a        temperature of approximately 120° Celsius by passing the cover        and inlay substrate over a hot lamination roll, under a pressure        of approximately 3 Bar.

The layers of the multi-layer inlay substrate (208) and the cover layer(204) may be handled in sheet format and not from a web or an endlessreel during the coating and lamination processes in which the material,held under tension, is passed over hot and cold rollers. Web coating andlaminating over rollers is the primary cause of curling of the finishedproduct.

To avoid the so-called banana effect of curling inlays after adhesivelyattaching the cover layer to the inlay substrate, the reactive hot meltadhesive may be applied to the cover layer in sheet format. For securityreasons, the peel strength of the laminated inlay with the cover layershould meet or exceed the ICAO standard (ISO/IEC 10373). This can beachieved by applying the correct thickness of adhesive during thecoating stage, exerting the correct pressure and temperature during thereactivation stage and storing the finished product to complete thecuring process in a moisture controlled environment.

An Alternative to Hot Melt Adhesive

In another embodiment of the invention, a solution is provided whichminimizes the emission of CO2 gas resulting in the formation of bubblesbetween a passport cover layer and the underlying inlay substrate.Instead of applying hot melt adhesive to the structured cover layerresulting in an uneven thickness of adhesive, a thin layer of aliphaticadhesive (as opposed to aromatic adhesive) high in viscosity (34,000mPas at 130° Celsius) may be applied with a short open time of severalseconds to the inlay substrate using a slot nozzle system (with shims)See, for example, Jowat 628.80.

In order to be able to apply the aliphatic adhesive under light pressureto the inlay substrate, it is advisable that the slot nozzle head doesnot go against the “grain” of the protruding antenna wires at theposition of the chip module. For this reason, the slot nozzle headapplying the adhesive may be applied in the direction of the wire ends,and not in the direction of the antenna.

After applying the aliphatic adhesive, but before the aliphatic adhesiveis reactivated, the hinge gaps may be punched in the inlay substrate.And, finally, the cover layer may be placed over the inlay substrate andlaminated in a press to create the passport cover.

Mechanically Milling the Recess

A problem with mechanical milling a synthetic material such as Teslin™is that it is a flexible (resilient, deformable). It is no problem topunch out a hole through a layer of Teslin™ and, as described above, astepped opening can be made by compression.

According to a feature of the invention, a recess (stepped or straight)can be formed in a material such as Teslin™ used for the inlay substrateby mechanical milling, by first reducing the temperature of the Teslin™to make it more rigid and machineable. For example, below −10° C., suchas approximately −18° C. Refrigeration and cooling units are well known.The material may be removed from the refrigeration unit immediatelyprior to machining (milling) and/or may be maintained at a lowtemperature during machining, such as by directing a stream of cooledair at the workpiece.

Numerous recesses in inlay substrates are illustrated herein, andmilling is well known. A suitable milling tool is available from IBAGSwitzerland AG, operating at 30,000 to 60,000 RPM, moving at 1-4 metersper minute (mpm).

Forming Recesses in Inlay Substrates, using Laser Ablation

US 20080179404 describes (see FIG. 8 therein) a technique for forming arecess in a substrate. As described therein . . . .

-   -   The laser 860 emits a beam (dashed line), targeted at the        substrate 802, to ablate material from the substrate 802 to form        the recess 806. The beam may have a diameter of approximately        0.1 mm. The beam may be scanned back and forth, traversing in        one direction entirely across the recess area, turning around,        and traversing back across the recess area, like plowing a        field. Many passes may be required to carve out the entire area        of the recess, given that the beam diameter is typically much        (such as 10-100 times) smaller than the length or width of the        recess. As is known, the beam may be scanned, in any suitable        manner, such as with mirrors. Also, the intensity of the beam        may be controlled or modulated to control the penetration into        the substrate. For example, a pulse-width modulated beam may be        used. The laser may be a UV laser (355 nm) with a power ranging        from 20 to 70 watts.    -   The process of using a laser in this manner, rather than (for        example) a conventional rotating milling tool, may be referred        to as “laser milling”. The technique described herein may be        particularly beneficial for applications where it is desired to        form a “pocket” type recess which intentionally does not extend        all the way through the substrate or sheet (in other words, the        recess or pocket extends only partially through the substrate).        Mechanical milling can be difficult. On the other hand, laser        milling can be very effective for Teslin and polycarbonate        substrates. For PVC, laser milling is less effective.

In another embodiment of the invention use is made of a Teslin™ inlaysubstrate to accommodate a 3up format (182.56 mm×404.81 mm) with athickness of 356 μm, prepared with milled cavities (laser abrasion ormechanically milled) with a depth of 95 μm on each side of an opening toaccept a leadframe or glass epoxy chip module. Before a chip module isplaced in each of the three pockets, as described, an ultra violetadhesive with reflecting particles is dispensed for the purpose ofholding a chip module in placed as well as a security feature toindicate tampering. In the next step of the process, an insulated selfbonding wire with a diameter of approximately 80 μm is embedded into theTeslin™ inlay substrate; scribing an antenna with 4 turns; looping thewire ends of the antenna adjacent to the terminal areas of a chipmodule; removing the wire insulation before interconnection, drawing thelooped wires on each side of the chip module over the terminal areas;and bonding the wire ends to the leadframe or glass epoxy tape by meansof thermo compression bonding. After bonding, the wire ends are deformedto a thickness of approximately 40 μm.

Given that the thickness of the chip module (leadframe: 80 μm and moldmass 240 μm) is approximately 320 μm and the inlay substrate 356 μm, theconnected antenna wires to the leadframe of the chip module may protrudeover the inlay by approximately 40 μm. The antenna is embedding entirelyinto the inlay substrate using an ultrasonic embedding head assemblywith booster, alternatively the antenna can be pressed into thesubstrate using a heated stamp the size of the antenna or laminated in aconventional press. Typically the lamination process results in theshrinkage of the inlay substrate, and therefore it can be advantageousto punch the hinge gap (106, FIG. 1G) in the inlay substrate afterlamination to remain in tolerance.

FIGS. 3A-3D illustrate various techniques for using a laser to ablatematerial in a controlled manner from a substrate such as an inlaysubstrate (such as 208) to form a recess (such as 126) extending into asurface of the inlay substrate.

FIG. 3A shows forming a recess (opening, window) in a single layer ofmaterial, such as a layer of Teslin™ for an inlay substrate (compare106, FIG. 1F), using laser ablation. This single layer of material mayalso be representative of each of the two layers in a multi-layer inlaysubstrate such as are shown in FIGS. 2A and 2B.

FIG. 3A illustrates an exemplary process 300 of forming a recess 316 inan inlay substrate 308, using a laser 360. The inlay substrate 308 maybe a single layer of Teslin (for example), having a thickness “t” of 355μm. A typical size (width dimensions) for the recess 316, to accommodatea chip module (such as 210) with a lead frame (such as 218), may beapproximately 5 mm×8 mm. The recess 316 may extend completely throughthe inlay substrate 308, resulting in a window-type recess. The recess316 may extend only partially, such as 260 μm through the inlaysubstrate 308, resulting in a pocket-type recess.

The laser 360 emits a beam (dashed line), targeted at the substrate 302,to ablate material from the substrate 308 to form the recess 316. Thebeam may have a diameter of approximately 0.1 mm. The beam may bescanned back and forth, traversing in one direction entirely across therecess area, turning around, and traversing back across the recess area,like plowing a field. Many passes may be required to carve out theentire area of the recess, given that the beam diameter is typicallymuch (such as 10-100 times) smaller than the length or width of therecess. As is known, the beam may be scanned, in any suitable manner,such as with mirrors. Also, the intensity of the beam may be controlledor modulated to control the penetration into the substrate. For example,a pulse-width modulated beam may be used. The laser may be a UV laser(355 nm) with a power ranging from 20 to 70 watts.

The process of using a laser in this manner, rather than (for example) aconventional rotating milling tool, may be referred to as “lasermilling”. The technique described herein may be particularly beneficialfor applications where it is desired to form a “pocket” type recesswhich intentionally does not extend all the way through the substrate orsheet (in other words, the recess or pocket extends only partiallythrough the substrate). Mechanical milling can be difficult. On theother hand, laser milling can be very effective for Teslin andpolycarbonate substrates. For PVC, laser milling is less effective.

The recess (opening) 316 formed in the inlay substrate layer 308 of FIG.3A extends completely through the inlay substrate layer 308. The layermay be representative of each of the at least two inlay substrate layers308 a and 308 b shown in FIGS. 2A and 2B which, to form a stepped recess(216) would have two different-size openings formed therein.

FIG. 3B shows forming a stepped window-type recess 316 r in a singlelayer of material, such a layer of Teslin™ for an inlay substrate 308 r(compare 108, FIG. 1H), using laser ablation. This may be a two-stepprocess comprising:

-   -   first laser milling a central area (such as between “b” and “c”)        to a first partially through the substrate,    -   then continuing laser milling the entire area (such as between        “a” and “c”) to create a recess extending partially through the        substrate in a peripheral area, and to extend the recess in the        central area completely through the substrate.        Alternatively:    -   first laser milling the entire area (between “a” and “d”) to a        first depth (d1)    -   then laser milling only the central area (between “b” and “c”)        to a second depth (d2).

FIG. 3C shows forming a stepped pocket-type recess 316 s in a singlelayer of material, such a layer of Teslin™ for an inlay substrate 308 s(compare 108, FIG. 1H), using laser ablation. This may be a two-stepprocess comprising:

-   -   first laser milling a central area (such as between “b” and “c”)        to a depth partially through the substrate,    -   then continuing laser milling the entire area (such as between        “a” and “d”) to create a recess extending partially through the        substrate in a peripheral area, and to extend the recess in the        central area deeper into (but not completely through) the        substrate.        Alternatively:    -   first laser milling the entire area (between “a” and “d”) to a        first depth (d1)    -   then laser milling the central area (between “b” and “c”) to a        second depth (d2).

FIG. 3D shows that a two-step pocket type recess 316 t can be formed ina single layer of material, such a layer of Teslin™ for an inlaysubstrate 316 t, using laser ablation. This may be a three-step processcomprising:

-   -   first laser milling a central area (such as between “c” and “d”)        to a depth partially through the substrate,    -   next laser milling a middle area (such as between “b” and “e”)        to a depth partially through the substrate, which will increase        the depth in the central area,    -   then continuing laser milling the entire area (such as between        “a” and “f”) to create a recess extending partially through the        substrate in a peripheral area, and to extend the recess in the        middle and central area deeper into (but not completely through)        the substrate.        Alternatively:    -   first laser milling the entire area (between “a” and “f”) to a        first depth (d1)    -   then laser milling the middle area (between “b” and “e”) to a        second depth (d2)    -   then laser milling the central area (between “c” and “d”) to a        third depth (d3).        For example, the resulting depths may be:    -   in the peripheral area (“a”-“b”, “e”-“f”), approximately 0.056        mm    -   in the middle area (“b”-“c”, “d”-“e”), approximately 0.116 mm    -   in the central area (“c”-“d”), approximately 0.306 mm    -   remaining thickness at the bottom of the central area,        approximately 0.050 mm    -   (total thickness of the substrate, 0.306+0.050=0.356)        Forming Channels in Inlay Substrates, for Mounting the Antenna        Wire

As mentioned above, the antenna wire may be mounted to the surface of aninlay substrate by ultrasonically embedding (countersinking) it into thesurface of the inlay substrate. Ideally, the antenna wire is fullyembedded so that it is flush or below the top surface of the inlaysubstrate.

With ultrasonic embedding, the wire may become only partially embedded,such as approximately half its diameter. In other words, a 100 μmdiameter wire may be embedded 50 μm (half its diameter) into the inlaysubstrate, and may protrude approximately 50 μm (half its diameter) fromthe surface of the inlay substrate. And, in the case of adhesivelysticking, a 100 μm diameter wire may be substantially not embedded atall into the inlay substrate, and may protrude approximately 100 μm (itsentire diameter) from the surface of the inlay substrate.

For applications such as driver's license or passports, it is generallynot desirable that the wire extend (protrude) above the surface of theinlay substrate. As discussed hereinabove, the chip module may berecessed so as to be substantially contained within the inlay substrate(or sheet), without sticking out and creating a bump.

According to an embodiment of the invention, the antenna wire may bemounted so as to be substantially entirely disposed (embedded) withinthe surface of the inlay substrate, without protruding therefrom. Inother words, the wire will be substantially entirely recessed below thesurface of the inlay substrate.

Generally, this may be accomplished by creating a “groove” (or“channel”, or “trench”) in the surface of the inlay substrate to acceptthe antenna wire. Then, the antenna wire may then be laid (inlaid,pressed, sunk) into the groove.

In general, the groove may be formed either by removing material fromthe substrate (by analogy, digging a trench with a shovel, and tossingthe dirt aside), or displacing material of the substrate (by analogy,hoeing a trench to push aside dirt). Some exemplary techniques forremoving or displacing material will be described below. A mechanicaltool, such as a wire bonder, may be used to form and press the wire intothe groove.

The depth of the groove should be at least a substantial portion of thediameter of the wire, such as at least 50% of the diameter of the wire,including at least 60%, at least 70%, at least 80% and at least 90%, andthe groove may be at least as deep as the wire diameter, such as atleast 100%, at least 105%, at least 110%. In some cases, describedbelow, the groove may be a “deep trench” which is much greater than thediameter of the wire, for routing the wire from one level, such as justwithin the surface of the substrate) to another level, such as deepwithin the substrate, such as for facilitating connecting the wire tocontact areas or pads of a module which are disposed below the surfaceof the substrate (see, for example, FIGS. 2B and 2D where the wire endsare bonded to a bottom surface of the leadframe, rather than to the topsurface thereof).

For example, for mounting a 60 μm diameter wire, a groove which isapproximately 60 μm deep may be formed into the surface of the inlaysubstrate. As discussed below, in conjunction with mechanicallyembedding the antenna wire in the groove, heat may be applied to allowfurther embedding. Therefore, for example, a 60 μm wire could bepressed, with heat, into a 40 μm deep groove, and become substantiallyentirely embedded within the surface of the substrate, withoutprotruding therefrom.

The groove may be less deep than the diameter of the wire and, as thewire is laid down into the groove, it may be pressed further into thesubstrate. Or, after the entire antenna wire is laid down, the inlaysubstrate may be placed in a press which may further sink the antennawire into the inlay substrate. The wire may be warmed. The process maybe performed in a warm environment to soften the substrate.

The width of the groove may be approximately equal to the diameter ofthe wire. For example, for a wire having a diameter of 60-80 μm, a laserbeam having a diameter of 0.1 mm (100 μm) would create a groovesufficiently wide (100 μm) to receive the wire. The groove may benarrower than the diameter of the wire, such as approximately 95% of thediameter of the wire, to facilitate an “interference” fit, securelyholding the wire in position for subsequent handling. In general, agroove which is significantly wider than the diameter of the wire wouldnot be preferred, since it would tend not to retain the wire (such as byinterference fit), without more (such as an adhesive).

The groove may be slightly narrower than the diameter of the wire, andas the wire is being laid down, the material of the inlay substrate mayresiliently retract (e.g., elastic deformation) to receive the wire,holding it in place. Generally, the wire typically has a circularcross-section (but may have other cross-sections, such as a ribbonwire), and the groove may have a substantially rectangularcross-section. For example, a 60 μm wide groove may receive and retainin place an 80 μm diameter wire. The wire may be warmed as it is beinglaid down (scribed, sunk) into the groove to facilitate its entry intothe groove.

The groove may simply be a channel extending along the surface of theinlay substrate, formed by a mechanical tool (ultrasonic stamp orscribe), or by a hot mold process. Alternatively, the groove may beformed by laser ablation, in a manner similar to how recesses are made(FIGS. 3A-3D).

Generally, the groove facilitates holding the wire in place. Forexample, a 100 micron diameter wire can be inserted (with some pressure)into a narrower, such as 95 micron wide channel (the depth of thechannel should be at least half the diameter of the wire, so that thewire can be embedded “over center”), and will stay in place. It isbeneficial that this can be done without requiring an ultrasonicembedding tool. As mentioned above, mounting a wire to the inlaysubstrate is typically done by ultrasonically embedding the wire intothe inlay substrate, or ultrasonically causing a self-bonding wire toadhere to the inlay substrate. The “channeling technique” disclosedherein can proceed faster than the ultrasonic techniques, and sheets canbe prepared with wire channels, off-line, then the wire can be installedin a simple embedding machine which does not need ultrasonics.

FIG. 4A (corresponding to FIG. 9 of US 20080179404) illustrates atechnique 400 a using a laser 460 a to form a groove (channel, trench)462 a in a surface of an inlay substrate 408. This is an example ofremoving material to form the groove. The laser 460 a is shown movingfrom left-to-right in the figure.

A wire 420 is shown being laid down into the groove 462, fromleft-to-right, and may be urged into the groove 462 by a simple pressingtool (or wheel) 468. The wire 420 may be laid into the groove 462 duringformation of the groove (channel), by following after the laser adistance “u”.

Although only one straight groove is shown, a 2-dimensional (x-y) groovepattern may thus be formed in the top surface of the inlay substrate,extending from (originating and terminating at) a recess in the inlaysubstrate, for embedding an antenna wire having a number of turns orcoils (see FIG. 1E). As mentioned above, insulated wire is relevantwhere the wire needs to cross over itself, such as at the point “c” inFIG. 1E. And, in some cases, the antenna wire does not need to crossover itself. See, for example, FIG. 4 of U.S. Pat. No. 6,698,089.

FIG. 4B illustrates a technique 400 b using a mechanical tool 460 b toform a groove 462 b in a surface of an inlay substrate 408. This is anexample of removing material to form the groove. The tool may be amilling tool, such as a conventional or climb milling tool availablefrom IBAG Switzerland AG, described hereinabove. Reducing thetemperature of the material being milled, as discussed above, may beemployed.

Alternatively, the tool 460 b may be similar to a “gouge” used to carvepatterns in wood. (Gouge—Carving tool with a curved cutting edge.) Agouging tool 460 b is shown moving from left-to-right in the figure. Inthis figure, the wire (420) and the pressing tool (468) are omitted, forillustrative clarity. The “debris” from gouging (or milling) is alsoomitted, for illustrative clarity. Reducing the temperature of thematerial being gouged may be employed.

FIG. 4C illustrates a technique 400 c using an ultrasonic stamp tool 460c form a groove 462 c in a surface of an inlay substrate 408. This is anexample of displacing material, with pressure, to form the groove. Thetool may be a thin rectangular block, or a small diameter cylinder,mounted to an ultrasonic converter (not shown). The tool 460 c is shownmoving from left-to-right in the figure. In this figure, the wire (420)and the pressing tool (468) are omitted, for illustrative clarity. Asimilar tool could be used to push the wire further into the substrate,once it has already been (partially) embedded therein.

FIG. 4D illustrates a technique 400 d forming a groove 462 d in thesurface of an inlay substrate 408 by using heat and molding.Essentially, a die tool 460 d having a raised pattern 461 correspondingto the desired pattern for the groove(s) is pressed (arrow) down againstthe surface of the inlay substrate, and heat may be applied, to transferthe pattern to (mold the pattern into) the inlay substrate. Thistechnique can also be considered to be “displacing”.

Regarding techniques for displacing material to form a channel for theantenna wire, it could be said that in straightforward embedding(ultrasonic, sonotrode), the wire displaces substrate material as it isembedded into the surface of the substrate. It should be understood thatthe displacing techniques described herein are performed with a toolseparate and distinct from the wire, and prior to the wire beingembedded in the surface of the substrate.

It should be understood that the channels for antenna wire beingdiscussed herein are “pre-formed” (prior to mounting/embedding theantenna wire therein) in a desired pattern for the antenna. An inlaysubstrate may be prepared with such pre-formed channels for laterembedding of antenna wire.

It should be understood that when a wire is inserted (mounted) into apre-formed groove, this is different than ultrasonic embedding into anon-grooved surface of a substrate, such as is disclosed in U.S. Pat.No. 6,698,089. A tool for mounting the wire into a pre-formed groove mayor may not be ultrasonic. Although the word “embedding” may be usedherein, in conjunction with mounting wires in pre-formed grooves, itshould be understood that it is used in its generic sense relating toinserting a first material (such as a wire) into a groove formed inanother material (such as the inlay substrate, or a given layerthereof).

FIGS. 4E and 4F are cross-sectional views of a substrate 408 with agroove 462 e (compare any of grooves 462 a, 462 b, 462 c, 462 d) and awire 620 mounted in the groove. A simple embedding tool 460 a may beused (such as without ultrasonics). FIG. 4E shows after grooveformation, prior to embedding. In FIG. 4F, the wire 420 is shown, afterembedding, protruding above the top surface of the substrate 608. Ifsufficient pressure, heat and/or ultrasonic are used during embeddingand/or the groove is sufficiently deep, the wire may be fully embedded,flush with the top surface of the substrate.

In FIGS. 4E and 4F, a channel 462 e is previously formed in a surface ofan inlay substrate (or in a surface of a layer of a multi-layersubstrate), and a wire 420 is mounted into the pre-formed channel 462 e.The wire may be completely inset into the substrate, or it may protrudeslightly therefrom.

FIGS. 4G and 4H illustrate that a channel 472 forming an antenna patternmay be formed in a layer 474 of adhesive (compare 209, 214) on thesurface of an inlay substrate 476 or layer of a multi-layer inlaysubstrate (compare 208, 408), and a wire 478 (compare 420) may bemounted therein using a tool 480 (compare 460 a). For example, theadhesive 474 may be 80 μm thick glue. The channel (groove, trench) 472may be, for example, 60-80 μm deep. The channel 472 may go all the waythrough the adhesive 474, and further into the substrate 476. Thechannel 472 may extend only partially through the adhesive 474, asindicated by the dashed line at the bottom of the channel 472.

The adhesive 474 may be polyurethane. Polyurethane, once beyond its“open time”, goes hard, making it ideal for trench formation. Later, forlaminating, it may be reactivated with a heat source, such as aninfrared light. Hence, the adhesive may be applied sufficiently inadvance of channel formation, such as 1-10 minutes (for example) before,to facilitate channel formation.

U.S. Provisional Patent Application No. 61/235,012 filed Aug. 19, 2009by Finn, discloses forming channels in an inlay substrate or in anadhesive layer on an inlay substrate, the channel forming a pattern foran antenna, and filling the channel with a flowable, conductive materialrather than mounting a wire therein. FIGS. 4I-4L herein correspond toFIGS. 6A-6D therein. The Provisional Patent Application also disclosestechniques for connecting the antenna formed by the filled channels withchip modules. FIGS. 4M-4P herein correspond with FIGS. 7A-7D therein.

FIG. 4I illustrates a substrate 408 having a channel (groove, trench)462 formed in a top surface thereof, and a quantity of flowable,conductive material 444 applied on the surface. Some of the material 444may be in the channel 462. The conductive material 444 is viscous, suchas metallic powder, conductive glue (see list above). A squeegee 446 isshown positioned above the material 444. The squeegee 446 will belowered (see arrow) so as to be substantially in contact with the topsurface of the substrate 408.

Exemplary (non-limiting) dimensions for the channel(s) 462 may be

-   -   60-80 μm deep    -   having a width of, for example, 50-100 μm.

FIG. 4J illustrates that as the squeegee 446 is advanced (see arrow), itforces the conductive material 444 into the channel 462. Residualconductive material 444 is substantially cleared from the surface of thesubstrate 408, but an additional cleaning step may be added.

FIGS. 4K and 4L are similar to FIGS. 4I and 4J, and show that thechannels can be formed in a layer 409 of adhesive on the surface of thesubstrate 408 and filled with conductive material 444. In this example,the adhesive 409 is 80 μm thick glue. The channel (groove, trench) 462may be, for example, 60-80 μm deep. The channel 462 may go all the waythrough the adhesive 409, and further into the substrate 608.

The adhesive 409 may be polyurethane. Polyurethane, once beyond its“open time”, goes hard, making it ideal for trench formation. Later, forlaminating, it may be reactivated with a heat source, such as aninfrared light. Hence, the adhesive may be applied sufficiently inadvance of channel formation, such as 1-10 minutes (for example) before,to facilitate channel formation.

FIG. 4M (compare FIG. 5A) illustrates an example of an inlay substrate708 having a recess 416 for receiving a chip module 410 (dashed lines),and a channel (or channel pattern) 440 formed in the top surface of theinlay substrate 408 for filling with a flowable, conductive material(not shown, see FIG. 4N). The recess 416 may be rectangular, forreceiving a leadframe-type chip module (compare FIG. 1C).

The channel (groove, trench, channel pattern) 440 (compare 462) may beformed in the inlay substrate 408 prior to the chip module 410 beingmounted in the recess 416 (and prior to filling the channel withconductive material), using any of the techniques disclosed in FIGS.4A-4D, or the like. An inlay substrate 408 with a channel 440 may beconsidered to be an “interim product”. The channel 440 may be filled asshown in FIGS. 4I-4J, and may be in an adhesive layer as shown in FIGS.4K-4L.

The channel 440 may comprise a first portion extending at one locationacross the recess 416, and a second portion extending at anotherlocation across the recess 416. More particularly, for example,

-   -   a first channel segment 440 a extends from a top portion of the        recess 416 in one direction (towards the left, as viewed) across        the surface of the substrate 408    -   a second channel segment 440 b extends from the top portion of        the recess 416 in another direction (towards the right, as        viewed) across the surface of the substrate 408, and may be        collinear with the first channel segment 440 a    -   a third channel segment 440 c extends from a bottom portion of        the recess 416 in one direction (towards the left, as viewed)        across the surface of the substrate 408    -   a fourth channel segment 440 d extends from the top bottom of        the recess 416 in another direction (towards the right, as        viewed) across the surface of the substrate 408, and may be        collinear with the third channel segment 440 c.

It should be understood that the terminal 410 a and 410 b may berepresentative of contact areas (rather than distinct terminals, on atop surface of a leadframe of the chip module 410.

The channel segments 740 a, 740 b, 740 c, 740 d (the entire pattern 740)are filled with conductive material 720.

FIG. 4N (compare FIG. 5B) is a cross-sectional view of the inlaysubstrate 408, showing:

-   -   the substrate 408    -   a “pocket” recess 416 extending into a top surface of the        substrate 408. (Although the recess 416 is shown as a “straight”        “pocket” type recess, for purposes of this embodiment, it is not        particularly important whether the recess is “stepped” or        “straight”, or whether it is “window” or “pocket”.)    -   a chip module 410 disposed in the recess 416    -   a terminal 410 a (which is one of two terminals) disposed on a        top surface of the chip module. (The terminal 410 a may be        representative of a contact area on a top surface of a leadframe        of the chip module 410.)    -   a channel 440 formed in a top surface of the substrate    -   conductive material 460 disposed in the channel 440

FIG. 4N shows laying an elongate conductive jumper 770 (such as a shortlength of wire) across the recess 416, extending over a terminal 410 a,and being bonded to the terminal 410 a, using a sonotrode 118 (source,FIG. 1F) for connecting the jumper 470 to the terminals 410 a of thechip module 410 (or connection areas of the leadframe). This is an“exploded” view.

As best viewed in FIG. 4M, to accommodate the jumpers 470, the channels440 may have enlarged regions “e” where they are adjacent the recess416. For example, whereas the channel 440 may be 60 μm wide, in the areaadjacent the recess, it may be 100 μm wide. In the regions “e” adjacentthe recess 416, the channels can also be deeper.

FIG. 4P shows the “finished product”, with the jumper 470 bonded to theterminals of the chip module.

FIG. 4Q illustrates a variation where elongate, conductive jumpers 472(compare 470) are initially bonded to the terminals 410 a of the chipmodule 410, before the chip module 410 is inserted into the recess 416.

In prior art printing techniques conductive ink is applied to thesurface of the substrate. The techniques are “additive” in nature.

According to the invention, by first having channels, the conductivematerial is embedded in the substrate, and may be flush with the surfacethereof. By not protruding therefrom, after subsequent lamination, thepattern of the antenna may not be evident.

Inlay Substrates having Channels

FIG. 5A illustrates an example of an inlay substrate 508 having a recess516 for receiving a chip module 510 (dashed lines), and a channel (orchannel pattern) 540 formed in the top surface of the inlay substrate508 for receiving an antenna wire (not shown, see FIG. 5B). The recess516 may be rectangular, for receiving a leadframe-type chip module(compare FIG. 1C).

The channel (groove, trench, channel pattern) 540 (compare 462) may beformed in the inlay substrate 508 prior to the chip module 510 beingmounted in the recess 516 (and prior to the antenna wire 520 beingmounted into the channel), using any of the techniques disclosed inFIGS. 4A-4D, or the like. An inlay substrate 508 with a channel 540 maybe considered to be an “interim product”.

The channel 540 may comprise a first portion extending at one locationacross the recess 516, and a second portion extending at anotherlocation across the recess 516. More particularly, for example,

-   -   a first channel segment 540 a extends from a top portion of the        recess 516 in one direction (towards the left, as viewed) across        the surface of the substrate 508    -   a second channel segment 540 b extends from the top portion of        the recess 516 in another direction (towards the right, as        viewed) across the surface of the substrate 508    -   a third channel segment 540 c extends from a bottom portion of        the recess 516 in one direction (towards the left, as viewed)        across the surface of the substrate 508    -   a fourth channel segment 540 d extends from the top bottom of        the recess 516 in another direction (towards the right, as        viewed) across the surface of the substrate 508

The first channel segment 540 a may be collinear with the second channelsegment 540 b, and may be positioned such that when the antenna wire(such as an end portion thereof) is laid in the channel segments 540 aand 540 b, the wire will extend directly above a first terminal 510 a(shown in dashed lines, compare 108 a, FIG. 1B) of the chip module 510,for connecting (such as by bonding) thereto. It should be understoodthat the terminal 510 a and 510 b may be representative of contact areas(rather than distinct terminals, on a top surface of a leadframe of thechip module 510.

The third channel segment 540 c may be collinear with the fourth channelsegment 540 d, and may be positioned such that when the antenna wire(such as an end portion thereof) is laid in the channel segments 540 cand 540 d, the wire will extend directly above a second terminal 510 b(shown in dashed lines, compare 108 a, FIG. 1B) of the chip module 510,for connecting (such as by bonding) thereto.

FIG. 5B is a cross-sectional view of a the inlay substrate 508 of FIG.5A, showing:

-   -   the substrate 508    -   a “pocket” recess 516 extending into a top surface of the        substrate 508. (Although the recess 516 is shown as a “straight”        “pocket” type recess, for purposes of this embodiment, it is not        particularly important whether the recess is “stepped” or        “straight”, or whether it is “window” or “pocket”.)    -   a chip module 510 disposed in the recess 516    -   a terminal 510 a (which is one of two terminals) disposed on a        top surface of the chip module. (The terminal 510 a may be        representative of a contact area on a top surface of a leadframe        of the chip module 510.)    -   a channel 540 formed in a top surface of the substrate    -   the wire 520, shown spaced above the channel 540    -   a tool 566 for pushing the wire 520 into the channel 540    -   a sonotrode 118 (source, FIG. 1F) for connecting the wire to        terminals of the chip module 510 (or connection areas of the        leadframe)

Starting with the interim product” comprising an inlay substrate 508with a channel 540, the chip module 510 may be disposed in the recess516 (optionally, with the cushion 542), and the antenna wire 520 may belaid into the channel, with the tool 566 urging the wire 520 into thechannel, as indicated by the vertical (downward-pointing) arrow. Thiswould generally be done by feeding the antenna wire from a spool (notshown), such as in a wirebonder apparatus, and pressing the wire intothe channel as it is fed from the spool, such asmillimeter-by-millimeter, as indicated by the horizontal arrow. In otherwords, the entire wire of the antenna (such as 4 or 5 loops) is notpressed all at once into the entire channel pattern.

The channel 540 may be slightly undersized (less wide than the diameterof the antenna wire), and the tool 566 may be heated to assist insertion(laying) of the antenna wire 520 into the channel 540.

Then, after the wire 520 is laid into the channel 540, it may be bonded,using the sonotrode 118, to the terminals of the chip module 510 (or toconnection areas of the leadframe of the chip module). In an exemplarywire-laying and wire-bonding sequence:

-   -   the wire 520 may first be inserted into the channel pattern 540        adjacent (such as 1 mm from) the recess 516,    -   then the wire 520 may be advanced over the recess 516 and a        corresponding terminal of the chip module 510, and bonded        thereto,    -   then the wire 520 may be advanced along the channel pattern 540        in the top surface of the inlay substrate 508 to form the loops        of the antenna,    -   then the wire 520 may be advanced again over the recess 516 and        a corresponding second terminal of the chip module 510 and        bonded thereto, and    -   then the wire 520 may be further advanced (such as approximately        1 mm) into the channel 540 adjacent the recess 516, and cut.

As disclosed in U.S. patent application Ser. No. 11/831,987 filed Aug.1, 2007 by Finn (Publication No. 2008/0073800; FIG. 6B therein), arecess may be sized and shaped to accommodate a thin layer of syntheticcushion material (such as silicone rubber) between the chip module andthe (underlying) substrate layer, to provide some protection againstshock, as well as against moisture.

FIG. 5B illustrates that, optionally, a thin layer 542 of syntheticcushion material is shown disposed under the chip module 510, at thebottom of the recess 516. This cushion feature is applicable to any ofthe embodiments disclosed herein having a pocket-type recess, or somesupport layer under a window-type recess.

U.S. patent application Ser. No. 11/773,434 filed Jul. 1, 2007(Publication No. 2008/0155822), incorporated by reference herein, (see,e.g., FIGS. 2A, 2B, 3A-3E, 4A-4E therein) discloses having a recesslarge enough that end portions of the antenna wire can extend across therecess, as wire “bridges” spaces sufficiently far apart from one anotherthat a transponder chip (module) being inserted past the spaced-apartwire bridges, followed by repositioning the wire bridges to be overcorresponding terminals of the transponder chip prior to bondingthereto. (A tool for repositioning the wire bridges to be over thetransponder chip terminals, for bonding thereto, is shown in FIG. 6B. Amethod is described with respect to FIG. 7 therein.)

U.S. patent application Ser. No. 11/831,987 filed Aug. 1, 2007 (seePublication No. 2008/0073800, e.g., FIGS. 3A-3D therein) discloseshaving a recess large enough that end portions of the antenna wire canextend across the recess, as wire “bridges” spaces sufficiently farapart from one another that a transponder chip (module) being insertedpast the spaced-apart wire bridges, followed by rotating the transponderchip, such as 90 degrees, so the terminals of the transponder chip areunder the wire bridges (which need not be repositioned) for bondingthereto.

FIG. 5C illustrates an example of an inlay substrate 508 having a recess516′ (prime) for receiving a chip module (not shown), and a channelformed in the surface of the inlay substrate for receiving an antennawire (not shown). The recess 516′ may be round (circular), for receivinga circular epoxy glass-type chip module (compare FIG. 1D). The recess516′ is similar to the recess 516 (FIG. 5A), and both may bemechanically milled (such as with cooling, as described herein), orlaser ablated.

FIG. 5D shows the chip module 510 disposed in the recess 516′. In thisexample, the chip module 510 may be an epoxy glass module. Notice thatthe chip module 510 is “upside down” (such as when contrasted with FIG.2J) in that the mold mass is on the top side, the FR4 substrate (orleadframe) is on the bottom, also the connection areas are on the topside of the FR4 substrate (or leadframe).

The connection areas on the chip module 510 are disposed well below(rather than substantially at the same level as) the top surface of thesubstrate 508. This shows the need to form a “deep trench” 521 from thetop of the inlay substrate 508, whereat the antenna wire 520 isembedded, deeper down into the substrate to be at the “sunken” level ofthe connection areas on the chip module 510. The deep trench 521 allowsfor routing of end portions of the antenna wire 520 down through theinlay substrate 508 (or layer of a multi-layer inlay substrate) to thecontact pads (or areas) on the chip module.

A cover layer 504 is shown over the inlay substrate 508. A film or layer542 of material, such as Teslin™, having a thickness of approximately 10μm, may be disposed over the chip module and antenna connections, withina top portion of the recess 516′. This film or layer may be referred toas a “lid”, or “cover”, and is discussed in greater detail with respectto FIGS. 6A and 6B.

A “deep trench” is essentially a channel (compare FIGS. 4A-4D) which,rather than traversing the substrate at a substantially constant depth,such as 40 μm, may ramp down (or be “inclined”), as illustrated in FIG.5B, so that the antenna wire (520) can reach a deeper level in thesubstrate 508, such as more than 100 μm. Generally, using laserablation, several passes may be required to form such a deep trench,since each as of the laser may only be able to ablate 5-10 μm ofmaterial. (A few passes of the laser would also be required for achannel that is deeper than the amount of material which can be ablatedin a single pass of the laser.)

Lids (or Covers) covering the Openings of the Recess(es)

In various embodiments described above, a recess (such as 216, 216′) forthe chip module (such as 210) extends (i) completely through the inlaysubstrate from the top surface to the bottom surface thereof and, insome instances, (ii) only partially through the inlay substrate (such as208″) from a top surface thereof. The openings of the recesses (theopenings are where the recess enters/exits the substrate surface) shouldbe sealed to keep moisture out of the inlay substrate, particularly inthe area of the chip module and antenna connections.

The cover layer itself (such as 204), which is cold laminated to theinlay substrate, will typically covers the opening at the top surface ofthe inlay substrate (such as 208).

A patch (such as 230) may cover the inlay substrate and connections.And, as discussed above, instead of using a patch to hermetically sealthe area, a moisture curing adhesive or a potting material (such as 234,FIG. 2G) may be used.

FIG. 6A illustrates a relevant portion of an inlay substrate 608 havinga stepped recess 616 extending partially therethrough, from a topsurface towards a bottom surface thereof (compare the two step recess316 t in FIG. 3D). The inlay substrate 608 may be a single ormulti-layer substrate. A leadframe-type chip module 610 is showndisposed in the recess 616. An antenna wire 620 is embedded in the topsurface of the inlay substrate 608. End portions of the antenna wire areconnected to the top surface of the leadframe 618. (It is generallyimmaterial which kind of chip module is disposed in the recess, orwhether the recess is round or rectangular.)

In this “exploded view”, the cover layer 604 is shown space apart fromthe top surface of the inlay substrate 608, as is the adhesive layer 614for joining the cover layer 604 to the inlay substrate 608.

The recess 616 has a width dimension at the top surface of the inlaysubstrate. If the recess is round, the width dimension is a diameter.The chip module 610 and end portions of the antenna wire 620 areslightly, such as approximately 10 μm, recessed below the top surface ofthe inlay substrate 608.

A film or layer (patch) 642 of material, such as Teslin™, having athickness of approximately 10 μm, is disposed over the chip module andantenna connections, within a top portion of the recess 616. This filmor layer may be referred to as a “lid”, or “cover”.

As mentioned before, the cover layer (204) will cover the opening in therecess at the top surface of the inlay substrate. However, for an“interim product”, such as an inlay substrate with transponder (andantenna), and no cover layer (yet), it is important to protect the chipmodule in the recess. Hence, the lid 642 serves to protect the chipmodule in the recess.

If the lid 642 extends over the recess, rather than being level with thetop surface of the substrate, it may be desirable to remove the lid 642prior to laminating the cover layer 604 to the substrate 608.

FIG. 6B illustrates a relevant portion of an inlay substrate 608 havinga stepped recess 616 extending completely therethrough, from a topsurface to a bottom surface thereof (compare the two step recess 316 tin FIG. 3D). The inlay substrate 608 may be a single or multi-layersubstrate. A leadframe-type chip module 610 is disposed in the recess616. An antenna wire 620 is embedded in the top surface of the inlaysubstrate 608. End portions of the antenna wire are connected to the topsurface of the leadframe 618.

In this “exploded view”, the cover layer 604 is shown space apart fromthe top surface of the inlay substrate 608, as is the adhesive layer 614for joining the cover layer 604 to the inlay substrate 608.

The recess 616 has a width dimension at the top surface of the inlaysubstrate 608. If the recess is round, the width dimension is adiameter. The chip module 610 and end portions of the antenna wire 620are slightly, such as approximately 10 μm, recessed below the topsurface of the inlay substrate 608.

In a manner similar to FIG. 6A, a film or layer 644 of Teslin™(generally, the material for the lid can be the same material, differentthickness, as the inlay substrate), having a thickness of approximately10 μm, is disposed over the chip module 610 and antenna connections,within a top portion of the recess 616.

The recess 616 has a width dimension at the bottom surface of the inlaysubstrate 608. If the recess is round, the width dimension is adiameter. For a stepped recess, the width dimension at the bottom of theinlay substrate is typically less than the width dimension at the topsurface of the inlay substrate.

The chip module 610 (and mold mass) are slightly, such as approximately10 μm, recessed above the bottom surface of the inlay substrate 608. Afilm or layer 642 of Teslin™ (for example) having a thickness ofapproximately 10 μm, is disposed under the chip module 610, within abottom portion of the recess 616.

The top and bottom layers 642 and 644 may be referred to as “covers”, or“lids” since they are used to close off (seal, plug) the recess 616, byway of analogy in the manner of manhole covers. They may also bereferred to as “patches”. Generally, in contrast with a patch (such as230) which may be placed over the recesses, by virtue of the fact thatthe covers 642 and 644 fit into the recess 616, they do not add to theoverall thickness or surface flatness of the inlay substrate 608.

A Security Appliqué

In its broadest sense, an appliqué or appliqué is a smaller ornament ordevice applied to another surface. In the context of ceramics, forexample, an appliqué is a separate piece of clay added to the primarywork, generally for the purpose of decoration. The word appliqué is aFrench word that, in this context, means “that has been applied”.

Credit cards, for example, may have holograms on a surface thereof. In1984, most Visa™ cards around the world began to feature a hologram of adove on its face, generally under the last four digits of the Visa™number. This was implemented as a security feature. Similar changes wereimplemented with MasterCard™ cards. On most Visa™ cards, holding theface of the card under an ultraviolet light will reveal the dovepicture, as an additional security test. (On newer Visa cards, the UVdove is replaced by a small V over the Visa logo.)

FIG. 7A illustrates an “electronic ink” display (“applique”) which canbe activated by the electro-magnetic field (from a reader, not shown)driving the RFID chip, comprising the following elements:

-   -   734, a hologram, metal stripe or an electronic ink display which        can be activated by an electro-magnetic field to indicate        unauthorized tampering at the area surrounding the chip    -   736, inductive coupling antenna to drive the electronic ink        display

In this manner, when the secure document is being read (interrogated),the display will become visible. This enhances the security of thedocument.

FIG. 7B illustrates that the appliqué can be placed anywhere on theinlay 700. Here, it is shown in the middle of the antenna coils. Itcould be used, for example, as the bottom lid (642, FIG. 6B).

Personalizing the Substrate

FIG. 7C illustrates an inlay substrate 708 with additional securityfeatures. For example, an additional security feature may be using laserablation (see FIGS. 3A, 4A) to personalize the inlay substrate withpatterns of dots, lines, bar codes, symbols, numbers, letters, or thelike. This may be done in conjunction with other laser ablation steps(laser ablation of the recess 716 or channels), or in a separate laserablation step. And, instead of using laser ablation, any other process(such as stamping, printing, compressing, staining, watermarking, andthe like) may be used to personalize the substrate. The general idea isthat each inlay substrate is uniquely identified, and its identity canbe ascertained.

Anti-Skimming Features

Regarding skimming, two solutions are presented:

-   -   including aluminum metallic powder into the hotmelt adhesive        (209) or    -   embedding a de-tuning antenna into the substrate layer opposite        the transponder.

FIG. 7D illustrates a passport cover comprising a cover layer 704laminated with adhesive 714 to an inlay substrate 708. The black dots inthe adhesive layer 714 represent metallic powder.

FIG. 7E illustrates a shielding/detuning antenna 760 which may bedisposed on the back panel of the passport cover (see FIG. 1A). Theantenna 760 may be mounted to the top surface of the inlay substrate 708(compare 208) in the same manner as the antenna (220) for the chipmodule (210) is mounted (embedded). The same or different wire may beused.

The antenna 760 may make several, such as 9 or 10 turns, and may be open(ends not connected with one another). Exemplary dimensions (inmillimeters) are shown. For example, the back panel of the inlaysubstrate 708 may measure 88×125 mm, the antenna wire may be spaced 5 mmin from the edge of the substrate, and the coil “pitch” may be 3 mm,

The “de-tuning” antenna for shielding purposes can be an open circuitantenna tuned to half the resonance frequency of the transpondercircuit, approx. 7.5 MHz—or alternatively the detuning antenna can be aclosed circuit antenna in which both ends of the antenna are connected.

U.S. patent application Ser. No. 12/198,103 filed Aug. 25, 2008(Publication No. 2008/0308641), incorporated by reference herein,discloses: in order to prevent skimming and eavesdropping of thepersonal data stored in the memory of an RFID chip in an electronicpassport or secure document, it is proposed to use a de-tuning antennascribed into the substrate which forms part of the back cover of thepassport cover. The wire antenna made of copper and insulated isembedded from the center of the substrate to the perimeter leaving thewire ends open. When the passport cover is closed the de-tuning antennais positioned over the primary antenna connected to the RFID chip andseparated by the pages of the passport cover which act as a dielectricmedium. When the passport is in an electromagnetic field, the detuningantenna is coupled with the primary antenna resulting in the de-tuningof the complete system, making it substantially impossible to activatethe RFID chip with correct keys, and prevent reading or writing data tothe RFID chip. When the passport cover is opened and presented to areader, the de-tuning antenna is not positioned over the primary antennaconnected to the RFID chip, and it is possible to activate the RFIDchip.

Regarding de-tuning the antenna for the chip module, in addition to thetwo variations of open and closed circuit antenna, there is a thirdvariation which is an LCR circuit with the antenna tuned to halfresonant frequency of the transponder circuit, for example approximately7.5 MHz with the antenna inductor connected to a capacitor (100 pf) anda resistor (100 Ohm) in parallel—it is a filter circuit.

FIG. 7F shows (diagrammatically) a passport booklet, partially open,having a back panel and a front panel. In this example, the electronics(chip module and antenna) are located in the front panel. An actuator,which may be a strip of material, is fixed in the back panel (such asbetween the cover layer and the inlay substrate), and extends past thehinge area into the front panel. The actuator strip is not fixed in thefront panel, rather it is able to slide back and forth as the passportbooklet is opened and closed.

When the booklet is opened (curved arrow), the portion of the actuatorin the front panel moves (to the right, see right-facing arrow). The endof the actuator is conductive, and makes contact between two terminals(contacts) of the antenna wire. When the booklet is closed, the contactis broken. The end of the actuator and the two contacts associated withthe chip module's antenna constitute a switch disposed in the passportcover for disconnecting the chip module's antenna when the passportbooklet is closed. This provides security against skimming.

Some Features of the Antenna Wire

The antenna wire for the inlays described herein may compriseself-bonding copper wire or partially coated self-bonding copper wire,enamel copper wire or partially coated enamel wire, silver coated copperwire, un-insulated wire, aluminum wire, doped copper wire or litz wire.

The antenna wire may have a diameter of approximately 50-120 μm, and maybe coated with enamel so as to be insulated and/or “self-bonding”.

Insulated wire is relevant where the wire needs to cross over itself,such as at the point “c” in FIG. 1E.

Self-bonding wire is relevant to adhesively mounting the wire to thesurface of the inlay substrate (or a layer of a multi-layer inlaysubstrate).

An exemplary wire is Electrisola brand enamelled copper wire. 0.010-0.50mm (AWG 24-58) (0.010 mm=100 μm). A 112 μm wire may have only a fewmicrons of insulation on it. With an adhesive layer and an insulationlayer, the overall diameter may be 132 μm (for example).

FIG. 8A shows a self-bonding (of self-adhering) wire. Such self-bondingwire is described in U.S. Pat. No. 7,546,671, incorporated by referenceherein. The insulated, self-adhering wire 840 may comprise:

-   -   a metallic core 842, having a diameter;    -   a first non-metallic coating 844 disposed on the surface of the        metallic core 842; and    -   a second non-metallic coating 846 disposed on the surface of the        first metallic coating 844.

The core 842 may comprise copper, aluminum, doped copper, gold, or Litzwire, and may have a diameter of 0.010-0.50 mm (AWG 24-58) (0.010 mm=100micron).

-   Litz wire Litz wire is a special type of wire used in electronics.    It consists of many thin wires, individually coated with an    insulating film and braided, thus increasing the surface area of the    conductor and thereby reducing the skin effect and associated power    losses when used with high-frequency applications. The word    originated from Litzendraht, German for braids wire.

The first coating 844, or “base coat” may comprise modifiedpolyurethane, and may have a thickness of only a few microns.

The second coating 846, or “bond coat” may comprise polyvinylbutyral orpolyamide, and may have a thickness of only a few microns.

The composition of the insulated wire can have a base coat of modifiedpolyurethane and a bond coat of polyvinylbutyral or polyamide.

When mounting (adhesively placing) self-bonding wire, the wire coatingis chemically changed to react to the heat generated by the rubbing withthe ultrasonic horn (sonotrode). Additionally, ultraviolet (UV) lightradiation may be used, in a curing station. The self-bonding coatingaffords the strength of bonding (adhesively placing, or positioning) thewire to the substrate with the ultrasonic horn, while the UV lighthardens the adhesion.

In polymer chemistry and process engineering, “curing” refers to thetoughening or hardening of a polymer material by cross-linking ofpolymer chains, brought about by chemical additives, ultravioletradiation or heat.

The antenna wire for the inlays described herein may comprise a luminouscoating, which may be one of the coatings described immediatelyhereinabove with regard to the insulating and/or self-bonding wire. Byhaving a luminous coating, tampering with the antenna wire or the bondpositions can be exposed by presenting the inlay to an ultraviolet (UV)light source.

Removing Insulation From the Antenna Wire

With insulated wire, it may be advantageous to remove the insulationfrom at least a portion of the wire that will be bonded to the chipmodule. FIG. 7 of US 20080179404 is a cross-sectional view illustratinga technique for removing insulation from wire, according to anembodiment of the invention.

FIG. 8B illustrates removing insulation while mounting the wire. Anexemplary embedding tool 850 is shown. A wire 866 is shown passingthrough an eye 864 in a wire guide 860 of the embedding tool 850. An end872 of the sonotrode 870 pushes the wire against a substrate 844, formounting thereto. A wire cutter 846 is shown.

The purpose of the wire guide 860 is to guide wire 866 from an externalsupply (not shown) to under the end 872 of the sonotrode 870, so thatthe wire 866 can be embedded in to the surface of a substrate 844. Theend 862 of the wire guide 860 is provided with a small feed hole (or“eye”, as in eye of a needle) 864 through which the wire 866 can beinserted (or “threaded”, akin to threading a sewing machine needle). Thewire 866 can be seen passing through the wall of the wire guide 860, atapproximately a 45-degree (30-60 degree) angle.

Before passing through the eye 864 of the wire guide 860, the wire 866,which is a coated wire, passes through an insulation-removal station880, which may comprise a nozzle where laser light from a laser 882 canbe introduced via a glass fiber, to remove (ablate) the insulation fromthe wire 866. After passing through the insulation-removal station 880,the wire is no longer coated, as indicated by the primed referencenumeral 866′. As shown in the drawing, a distance “s” represents how farin advance, along the length of the wire, the insulation needs to beremoved to control its final destination.

Personalizing the Antenna Wire

FIG. 8C illustrates that the antenna wire 890 may be “personalized”, forexample stamped with a serial number, production batch number and ormanufacturer's code as an additional security feature. (Compare FIG. 7C,personalizing the substrate.)

Some Additional Features

Some additional features (embodiments) of the invention will now bediscussed. These features may be technical features, or securityfeatures. These features may be incorporated into the inlays, inlaysubstrates, and manufacturing processes described herein. These featuresmay be combined with other embodiments of the invention set forthherein.

FIGS. 8D and 8E correspond with FIGS. 5A and 5B of U.S. patentapplication Ser. No. 11/773,434 filed 1 Jul. 2007 by Finn (PublicationNo. 2008/0155822), incorporated by reference herein, and illustrate atechnique for connecting end portions of an antenna wire to an RFIDchip, which may be referred to as “direct connection”.

The technique to encapsulate a chip (die) in a thermoset plastic packageis commonly known as transfer molding. The molding material is highlyfilled epoxy primarily consisting of sand and glue, and also soot toprotect the die from ultraviolet light as well as antistatic, flameretardant (e.g. red phosphorous) and anti-stick (e.g. wax) compounds.

According to an embodiment of the invention, a transfer moldingtechnique is used, not for chip package encapsulation, but to hold thedie in a fixed position in a housing during the direct connection of thewire ends of an antenna to the aluminum pads on a silicon device or tobumps mounted on the aluminum pads.

FIGS. 8D and 8E illustrate a chip housing 800 with an opening 826 toaccept a die 808, and may be used to replace a conventional chip modulein manufacturing a transponder inlay. The die 808 is shown with twometalized bumps 808 a and 808 b on its front (top, as viewed) surface.The chip may have a generally rectangular shape, and the chip housing800 may have a similar (but larger) generally rectangular shape. Thebumps (connection areas) 808 a and 808 b can be enlarged or elongatedpads.

A substantially planar base portion 824 of the chip housing 800 has afirst dimension “x1” which may measure 8 mm, and a second dimension “y1”which may measure 8 mm, and has a thickness (“z1”) which may measure 100μm (0.1 mm). The thickness of the base portion 824 is intended tocorrespond (be substantially equal) to the thickness of the bottomlayer(s) 804 b (compare 104 b) of a multi-layered inlay 804 (compare104). These, and other dimensions set forth herein, are exemplary, andmay vary with different applications and configurations.

A wall portion 822 has four walls and protrudes from the top surface ofthe base portion 824, and is sized and shaped to surround a bare die808. For example, a die 808 may measure 1 mm×1 mm, and have a thicknessof 150 μm (0.15 mm). The opening 826 is shown, formed by the four wallsof the wall portion 822.

The four walls of the wall portion 822 rise from the base 824 and“frame” the die 808. The width and length of the wall portion 822depends on the size of the die. The four walls may each have a thicknessof approximately 0.5 mm (500 μm), so that the wall portion 822 has anoverall first dimension “x2” measuring 2 mm, and an overall seconddimension “y2” measuring 2 mm. The support portion may have a height(“z2”) of 200 μm (0.2 mm), which is intended to correspond (besubstantially equal) to the thickness of the upper layer(s) 804 a(compare 104 a) of the multi-layered inlay 804.

As best viewed in FIG. 8D, protruding from the center of the baseportion 824, within the wall portion 822, is a support portion 828 uponwhich the die 808 may be supported. The height of the support portion(200 μm) including the underlying base portion (100 μm) is approximatelyequal to the thickness of the inlay (300 μm), before this inner sandwichis laminated with a top and bottom layer. A hole 829 may be providedfrom the bottom of the base portion 824 through the center of thesupport portion 528 to allow for the passage of a heating element or fordispensing a substance. The support portion 828 may be formed integrallywith the base and wall portions, or may be an insert disposed within theopening 826.

As mentioned above, the housing 800 has a wall portion 822 extendingvertically from the base portion 824. Top surfaces of the wall portion822 are provided with grooves within which end portions 810 a and 810 b(compare 210 a/b, 310 a/b, 410 a/b) may be positioned prior to disposingh the chip 808 in the opening 826. The opening 826 corresponds to theaforementioned recesses (206, 306, 406), and the end portions 810 a and810 b of the antenna wire 810 span (bridge) the opening 826, and arespaced sufficiently wide apart that the chip may be inserted past theend portions 810 a and 810 b of the wire 810, into the opening 826.Initially, the end portions 810 a and 810 b of the wire 810 are“pre-positioned” and may be located in a pair of grooves 830 a and 830 bwhich extend across the top surface of the housing portion 822.

The grooves 830 a and 830 b may be generally semi-circular, and extendin parallel across the top surface of the housing portion 822, spaced adistance (“s8”) apart which is greater than a corresponding dimension(“w9”) of the chip 808. With the end portions 810 a and 810 b of theantenna wire 810 disposed in this first set of grooves 830 a and 830 b,and if these grooves are over the opening, the laser may be used toremove insulation from the end portions 810 a and 810 b of the antennawire 810, before positioning the wire ends of the antenna into a secondset of grooves 832 a and 832 b which are spaced a distance (“s9”) apartso as to be over the terminal areas of the chip 808. During insulationremoval, reflective material such as a mirror can be used to ensure thatthe insulation is completely removed from all sides of the wireconductor.

The opening (or recess) is only slightly larger than the chip, and theend portions of the wire (wire bridges) are directly moved from aninitial position which is wider than a width dimension of the chip (orchip module) to a final position which is narrower and places the wirebridged over the terminals of the chip for bonding thereto.

A procedure to produce an inlay with an array of transponder sites maybe as follows: Firstly, a cavity is punched at each transponder site inthe bottom layer(s) of an inlay sheet or substrate to accommodate thebase of the chip housing and cavities are also punched through the innerlayers to accommodate the support; Secondly, slots on each side of acavity can be provided in the top layers of the inlay to allow for easymanipulation of the wires in bringing them into position over theterminal areas of the chip; thirdly, a chip housing is inserted into theinlay at each transponder site and supported by an underlying layer;fourthly, an antenna is mounted at each transponder site in the array,passing the antenna wire over the slots and aligning the wire ends ofthe antenna adjacent to the cavity containing the chip housing; fifthly,in preparation for interconnection, the insulation from the wire ends ofthe antenna is removed; and finally, a chip is placed in the recess atthe apex of the housing and the un-insulated wires are aligned over theterminal areas for bonding.

Fiducials

As disclosed in FIGS. 4A and 4B of U.S. Provisional Application61/145,971 filed 21 Jan. 2009, the antenna for a passport inlay may havea special design with a “squiggle radius” at each corner of the antenna.For example, the antenna wire may be “looped” around the terminal areasof a chip module and embedded at the start and end of an antenna in acertain way or shape, to allow immediate recognition of the originalinlay manufacturer. The four radii (rounded corners) of the antenna maybe “squiggled” at each radius during the embedding process.

FIG. 8F illustrates two end portions 820 a and 820 b of an antenna wire820 passing over corresponding two terminals 810 a and 810 b of atransponder chip (or chip module) 810, and bonded (dots) thereto. Thechip module 820 is disposed in a recess 816 which is slightly largerthan the chip module. Fiducials (+) may be printed on the inlaysubstrate adjacent (near) the recess.

The end portions 820 a and 820 b of the antenna wire 820 are both showncrossing over the terminals 810 a and 810 b in an upward direction. Notethat prior to crossing over the terminals, the end portions of theantenna wire turn inward, then upward, and after crossing over theterminals, the wire. Then the end portions of the antenna wire turnoutward, and “wrap” around the upper left and right fiducials. Thisprovides for quality control, alignment and security.

An Ultrasonic Embedding Tool Of The Prior Art

FIG. 10A shows a sonotrode (wiring device for wiring a wire conductor bymeans of ultrasound) of the prior art, such as from U.S. Pat. No.6,698,089. As described therein (with reference to FIG. 3 therein,numbering preserved herein):

-   -   FIG. 3 shows the wiring device 22 in an individual        representation with an ultrasonic generator 34 which is arranged        coaxially with respect to the wire guide 23 and is rigidly        connected to the latter in a connecting region 35. Overall the        wiring device 22 represented in FIG. 3 is of rotationally        symmetrical construction. The wire guide 23 comprises a central        longitudinal bore 36 which in the region of the wire-guide        nozzle 30 merges with a wire capillary 37 which in comparison        with the longitudinal bore 36 has a narrowed diameter that is        matched to the diameter of the wire conductor 20. The        wire-guidance capillary 37 serves primarily to be able to align        the wire conductor exactly in the wiring plane 28 (FIG. 1).    -   In the embodiment example represented in FIG. 3 there are        arranged to the side of the wire guide 23, above the wire-guide        nozzle and leading into the longitudinal bore 36, two wire-feed        channels 38, 39 which extend obliquely downwards in the        direction of the wire-guide nozzle 30. The wire-feed channels        38, 39 serve for lateral introduction of the wire conductor 20        into the wire guide 23, so that the wire conductor 20, as        represented in FIG. 3, extends laterally on a slant into the        wire-feed channel 38, through the longitudinal bore 36 and,        guided out of the wire-guidance capillary 37, through the wire        guide 23. In this case the multiple arrangement of the wire-feed        channels 38, 39 permits selection of the wire-supply side of the        wire guide 23 that is most favorable in the given case.    -   As is further evident from FIG. 3, the wire-guide nozzle 30 is        of convex construction in the region of a wire outlet 40 in        order to enable a deflection of the wire conductor 20 that is as        non-damaging as possible in the region of the contact point 32        (FIG. 1) or in the region of the wire outlet 40 in the course of        the wiring operation represented in FIG. 1.    -   Although not represented in any detail in FIG. 3, the wire guide        23 may be equipped with a wire-severing instrument and a        wire-advancing instrument. In this case the wire-severing device        may be directly integrated into the wire-guide nozzle 30. FIG. 4        shows a wire conductor 20 which, for the purpose of forming a        coil 41 which in this case takes the form of a high-frequency        coil, is wired on a substrate 42. The coil 41 here has a        substantially rectangular configuration with an initial coil        region 43 and a final coil region 44 which are guided away via a        window-shaped substrate recess 45. In this case the initial coil        region 43 and the final coil region 44 are in parallel alignment        with a main coil strand 46 which they accept between them in the        region of the substrate recess 45. In the course of the        ultrasonic wiring of the wire conductor 20 already elucidated in        principle with reference to FIG. 1 the ultrasonic loading of the        wire conductor 20 is interrupted while the latter is being        guided away via the substrate recess in the course of the wiring        operation, in order on the one hand to ensure no impairment of        the alignment of the wire conductor 20 in an unrestrained region        47 between the recess edges 48, 49 located opposite one another        and on the other hand in order to rule out stressing of the        connection between the wire conductor 20 and the substrate 42 in        the region of the recess edges 48, 49 by tensile stresses on the        wire conductor 20 as a consequence of ultrasonic loading.        A Cantilevered Sonotrode

In an embodiment of the invention, the apparatus to countersink a wireinto a Teslin™ substrate, transforms ultrasonic energy operating at 60KHz from an ultrasonic converter to a sonotrode via a booster block. Thebooster block made of aluminum or titanium is bolted to the converterand the sonotrode, transporting ultrasonic energy with no loss ofamplitude from the converter to the sonotrode. To enhance the bundlingof ultrasonic energy to the sonotrode, the booster block can be shapedto direct the energy to the sonotrode. FIG. 5 is a production-typedrawing, with various views, illustrating an ultrasonic embedding tool.

According to an embodiment of the invention, an ultrasonic wire guidetool 900 comprises: an ultrasonic converter 901; an aluminum block 902bolted to the ultrasonic converter for the purpose of directingultrasonic energy to the sonotrode 903; and a capillary 904 comprising awire feed channel entering at the top of the aluminum block 902, passingthrough the sonotrode 903, and exiting at the tip 905 of the sonotrode;a compressed air connection (906) to facilitate the movement of a wire907 through the wire feed channel and a sonotrode (903) blotted to thealuminum block 902 and in use is oriented so that the tip of thesonotrode is perpendicular to the surface of the substrate.

In another embodiment a UV laser, may be provided for removinginsulation from a wire 907, in a controlled manner, prior to the wirepassing through the capillary (904) in the aluminum block 902. (CompareFIG. 8B)

The technique differs significantly from the technique described in,U.S. Pat. No. 6,698,089 which discloses that the ultrasonicgenerator/converter is arranged coaxially with respect to the wire guide(23) (sonotrode) (see for example claim 5 of the '089 patent). In theultrasonic wire guide tool 900 disclosed herein, converter 901 and wireguide 903 are not coaxial, but have axes offset from one another. Inthis sense, the sonotrode is cantilevered with respect to the ultrasonicconverter.

FIGS. 10B and 10C illustrates an ultrasonic wire guide tool 1000,generally comprising:

-   -   an ultrasonic converter 1001    -   an aluminum block 1002 bolted to the ultrasonic converter 1001    -   a wire guide or sonotrode 1003 bolted to the aluminum block 1002        (FIG. 10C, detail of sonotrode)    -   a wire feed channel 1004 in the aluminum block 1002 oriented        perpendicular to the ultrasonic converter 1001 and passing        through the wire guide or sonotrode 1003 and existing at the tip        of the sonotrode    -   an entry point 1005 at the tip of the sonotrode and    -   a compressed air connection 1006 to facilitate the movement of a        wire 1007 through the aluminum block 1002 and sonotrode 1003        (wire 1007 omitted from FIG. 10B, for illustrative clarity)

The ultrasonic embedding head or commonly known as a sonotrode resonatesat the ultrasonic generator frequency of approximately 60 KHz using anembedding tool made of titanium. Because the sonotrode directly embedsinsulated wire into a synthetic substrate like Teslin™, there isenormous abrasion at the tip of the sonotrode tool. To counter act theeffects of abrasion, the sonotrode is fitted with a hard metal insertwhich significant increases its life time. But because the hard metalinsert changes the resonant frequency of the original titanium shapedsonotrode, the form of the sonotrode is altered by removing metal tobring the sonotrode back to its original resonant frequency. Accordingto the embodiment of this invention, the sonotrode is not provided witha hard metal insert to increase its longevity, but rather the tip of thetitanium sonotrode is nitride hardened and or coated with diamond likecarbon (DLC).

The aluminum block may be designed to have the same resonance frequencyas the sonotrode, approximately 60 KHz.

An advantage of the aluminum “interface” block 902 is that by offsettingthe sonotrode 1003 from the converter 1001, the wire 1007 may be fedalong the axis of the sonotrode 1003, without needing to bend or be fedfrom the side. This “straight through” wire feed feature simplifies thedesign of the sonotrode, and minimizes dragging forces (stiction) on thewire 1007. Compare, for example, the prior art sonotrode in FIG. 10A inwhich “wire-feed channels 38, 39 serve for lateral introduction of thewire conductor 20 into the wire guide 23”.

While the invention has been described with respect to a limited numberof embodiments, these should not be construed as limitations on thescope of the invention, but rather as examples of some of theembodiments. Those skilled in the art may envision other possiblevariations, modifications, and implementations that are also within thescope of the invention, based on the disclosure(s) set forth herein.

What is claimed is:
 1. A method of making a secure document comprisingan inlay substrate, comprising: providing the inlay substrate as atleast two layers of a synthetic material laminated to one another with alayer of adhesive; and providing a recess for a chip module in thesubstrate; futher comprising: disposing ferrite particles in at leastone of the layers.
 2. The method of claim 1, wherein: the recess extendsthrough a top of the two layers and at least into a bottom of the twolayers.
 3. The method of claim 1, further comprising: disposing anantenna wire between the at least two layers.
 4. The method of claim 1,further comprising: forming the recess as a stepped recess having afirst opening having a first width dimension in a first one of the atleast two layers, and a second opening having a second width dimensionin a second one of the at least two layers which is adjacent to thefirst one of the at least two layers and the second opening is alignedwith the first opening.
 5. The method of claim 1, further comprising:forming the recess as a pocket-type recess extending only partiallythrough the substrate.
 6. A method of making a secure documentcomprising an inlay substrate, comprising: providing the inlay substrateas at least two layers of a synthetic material laminated to one anotherwith a layer of adhesive; and providing a recess for a chip module inthe substrate; further comprising: forming the recess by laser ablation.7. A method of making a secure document comprising an inlay substrate,comprising: providing the inlay substrate as at least two layers of asynthetic material laminated to one another with a layer of adhesive;and providing a recess for a chip module in the substrate; furthercomprising: forming channels in a surface of the substrate within whichan antenna wire may be at least partially embedded.
 8. The method ofclaim 7, wherein: the channels are formed by removing material ordisplacing material.
 9. The method of claim 7, wherein: the channels areformed by at least one of laser ablation, gouging, ultrasonic stamping,and heating and molding.
 10. The method of claim 6, wherein: the recessextends through a top of the two layers and at least into a bottom ofthe two layers.
 11. The method of claim 7, wherein: the recess extendsthrough a top of the two layers and at least into a bottom of the twolayers.
 12. The method of claim 1, further comprising: forming therecess as a window-type recess extending completely through the inlaysubstrate.
 13. The method of claim 6, further comprising: forming therecess as a pocket-type recess extending only partially through thesubstrate.
 14. The method of claim 6, further comprising: forming therecess as a window-type recess extending completely through the inlaysubstrate.